Transmission, Removing And Installing, Hybrid Vehicles: Removing

WARNING: This page is about a different car, the 2014 Volkswagen Touareg, 2013 Volkswagen Touareg, 2012 Volkswagen Touareg, and 2011 Volkswagen Touareg. However, it is still accessible from the selected car via links, so may be relevant.

WARNING:

High-voltage on the hybrid vehicle high-voltage system. Risk of electric shock! The following procedure requires work on the high-voltage system. De-energize the high-voltage system. Refer to DISABLING THE HIGH VOLTAGE SYSTEM RESTARTING THE HIGH VOLTAGE ELECTRICAL SYSTEM .

NOTE:

A :VAS-5085 is required to remove the transmission.

-- Remove the engine cover.

-- The procedure for disconnecting the batteries must be followed.

-- Disconnect the battery ground cable when the ignition is off. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the front and rear driveshafts. Refer to DRIVESHAFT .

-- Remove the left and right catalytic converters. Refer to CATALYTIC CONVERTERS, REMOVING AND INSTALLING [CGRA] , EMISSIONS CONTROL [CGFA] and EXHAUST SYSTEM COMPONENTS [CATA] .

-- Remove the right heat shield from the transmission.

-- Remove the bolts -1 and 2- and then remove the ATF lines from the transmission. Collect the escaping oil.

Fig 1: Identifying Transmission Fluid Pipe Bolts -1 And 2

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-- Seal the ATF lines using suitable plugs from the :VAS6122 .

-- Disconnect connectors -1, 2 and 3- from the transmission.

Fig 2: Connect Connectors -1 Through 3-

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-- Disconnect the connector -1- from the Transmission Fluid Auxiliary Hydraulic Pump 1 -V475- -2-.

Fig 3: Disconnect The Connector -1- From The Transmission Fluid Auxiliary Hydraulic Pump -V475- -2-.

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-- Disconnect the connector -1- from the Multifunction Transmission Range Switch -F125- -2-.

Fig 4: Connect The Connector -1- To The Multifunction Transmission Range Switch -2-.

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-- Disconnect the selector lever cable from the ball head -1- using the :80-200 and remove the lock washer -3-.

Fig 5: Identifying Selector Lever Cable, Removal/Installation

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NOTE:

A removed lock washer must not be used again. Always replace the lock washer.

Do not bend or kink the selector lever cable.

Ignore -item 2-.

-- Insert the guide pin for the :T40058 as follows:

Fig 6: Guide Pin And Adapter T40058

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The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

-- Counterhold the crankshaft with the :T40058 and an offset open-end wrench to loosen the drive plate bolts.

Fig 7: Counter Hold Crankshaft Using Socket T40058

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NOTE:

Turn the crankshaft only in the direction of engine rotation -arrow-.

-- Remove the cap -1-. Remove the three torque converter nuts -arrow- through the opening in the transmission. Turn the crankshaft 120° for this purpose.

Fig 8: Cap And Torque Converter Bolts

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Replace the nuts after removal.

-- Remove the transfer case. Refer to TRANSFER CASE, REMOVING AND INSTALLING .

The :VW 785/1 B needed for the transfer case removal must now be taken off again.

-- Fasten The Engine Support Bridge To The Body. Refer to ENGINE, REMOVING AND INSTALLING [CGRA] , ENGINE AND TRANSMISSION [CATA] and ENGINE, REMOVING AND INSTALLING [CGFA] .

-- Support the engine and transmission from above and release the tension on the :VW 785/1 B using the spindle and remove.

-- Place the :VAS6931 with the retrofitted :T40173 on the bottom of the transmission, and secure the transmission with a strap if possible.

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-- Relieve the load on the engine and transmission at the top via the engine support.

-- Lower the transmission slightly using the :VAS6931 .

Fig 9: Identifying Pre-Heater Bolts

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-- Remove the ATF preheater -arrows- from the transmission.

-- Remove the right catalytic converter bracket -A-.

Fig 10: Catalytic Converter Bracket Bolts

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-- Remove bleeder hose -B- from the clip.

-- Remove the left catalytic converter bracket -A-.

Fig 11: Identifying Left Catalytic Converter Bracket Bolts -Arrows- And Bracket -A-, Removal/Installation

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NOTE:

The two transmission/drive motor connecting bolts are removed at the same time as the left and right catalytic converter brackets.

-- Support the engine at the top.

-- Remove the remaining bolts -1 through 10- from the transmission.

Fig 12: Bolt Tightening Sequence

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-- Remove the transmission from the Electric Drive Motor.

NOTE:

Make sure the torque converter cannot slip out of the transmission during the removal procedure.

-- Remove the transmission downward using the :VAS6931 .

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-- After removing the transmission, use a :30-211 A to secure the torque converter from falling out.

Fig 13: Identifying Bracket -30-211A- Attached To Secure Torque Converter

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