Transmission, Removing And Installing, Vehicles With V6 TDI Engine: 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.

-- If the vehicle has air suspension, activate the vehicle lift mode. Refer to VEHICLE LIFT MODE .

-- Carefully remove the engine cover from the 4 retaining pins one after the other -arrows-.

Fig 1: Identifying Removal Of Engine Cover From 4 Ball Studs -Arrow-

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

-- Remove bracket -1- from the bulkhead -arrow-, so that the engine does not bump into the bracket when tilted.

Fig 2: Loosen The Nut -Arrow- And Remove The Bracket -1- From The Bulkhead

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-- Remove the noise insulation under the engine and transmission. Refer to OVERVIEW - NOISE INSULATION / OVERVIEW - UNDERBODY TRIM PANELS .

-- Remove the noise insulation bracket -arrows-.

Fig 3: Identifying Bracket For Noise Insulation

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-- Remove the rear section of the exhaust system. Refer to MUFFLER AND CATALYTIC CONVERTERS [CGRA] , EMISSIONS CONTROL [CGFA] and EXHAUST SYSTEM COMPONENTS [CATA] .

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

-- Remove The Diesel Particulate Filter. Refer to PARTICULATE FILTER, REMOVING AND INSTALLING [CATA] .

-- Disconnect the connectors -1 through 3- from the transmission.

Fig 4: Connect Connectors -1 Through 3-

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-- Secure the :T40091/1 using the :T40091/4 , :T40091/5 and :T40093/6 to the body. For this purpose, screw in screws -A- (M8 x 30) next to the large opening -arrow- in the body.

Fig 5: Crossmember T40091/1 With The Adapters

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-- Insert the :T40091/6 with the :T40091/7 into the :T40093/6 .

-- Then mount the :T40091/6 and the :T40091/8 on the automatic transmission housing.

-- Remove the transfer case -B- with the transmission support -C-. Refer to TRANSFER CASE, REMOVING AND INSTALLING .

-- 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] .

NOTE:

The special tools needed for removing the transfer case must now be removed.

-- Support the engine with the engine support bridge from above, lower the transmission via the :T40091/6 and remove the :T40091/1 with the Adapters underneath the transmission.

-- Remove the heat shield -A- from the steering gear.

Fig 6: Identifying Steering Gear Heat Shield -A-

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NOTE:

Only disconnect universal joint from steering gear if front wheels are in straight-ahead position.

To maintain the position of the steering wheel and steering gear, secure the steering wheel with adhesive tape.

-- Remove universal joint screw -B- and then remove the universal joint from the steering gear.

-- Remove The Catalytic Converter. Refer to CATALYTIC CONVERTERS, REMOVING AND INSTALLING [CGRA] , EMISSIONS CONTROL [CGFA] and EXHAUST SYSTEM COMPONENTS [CATA] .

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

Fig 7: Identifying Selector Lever Cable, Removal/Installation

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

NOTE:

Do not bend or kink the selector lever cable.

-- Remove catalytic converter bracket -1- from the transmission -arrows-.

Fig 8: Catalytic Converter Bracket Bolts -Arrows- And Bracket -1

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-- Remove heat shield -1- (for the coolant lines) and -2- (for the selector lever cable) from the transmission. Remove the screws -arrows A- and -arrows B-.

Fig 9: Heat Shield & Bolts

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-- Remove the vacuum hose -1- from the vacuum pipe -2- (leading to the brake booster).

Fig 10: Identifying Vacuum Hose & Pipe

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-- Place the :VAS6208 under the engine/transmission.

-- Clamp off the coolant hoses on the left side of the transmission with :3094 .

Fig 11: Coolant Hoses & Hose Clamps Up To 25 Mm Dia. 3094.

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-- Then remove the hose clamps from coolant pipes -A- using, for example, :VAG1921 . Remove the coolant hoses from the coolant pipes.

-- Clamp off the coolant hoses on the right side of the transmission with :3093 and disconnect the coolant hoses from coolant pipes -A-.

Fig 12: Coolant Pipes -A- & Hose Clamps Up To 40 Mm Dia. 3093

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-- Remove the bleed hose -B- from the clip on the coolant pipe.

Fig 13: Coolant Pipes, Breather Hose & Clips

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-- Remove the coolant pipes -A- from the transmission -arrows-.

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

Fig 14: Identifying Transmission Fluid Pipe Bolts -1 & 2

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-- Seal the ATF lines with suitable plugs from the :VAS6122 (to prevent dirt from getting into the lines).

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

Fig 15: Identifying Pre-Heater Bolts

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-- Disconnect the connector -1- from the Cooling Oil Valve -N471- -2- and remove the ATF preheater with the coolant pipes from the transmission.

Fig 16: Cooling Oil Valve -N471-

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-- If equipped, disconnect the connector -1- from the Transmission Fluid Auxiliary Hydraulic Pump 2 -V476- -2-.

Fig 17: 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 18: Connect The Connector -1- To The Multifunction Transmission Range Switch -2-.

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-- Remove the starter. Refer to STARTER, VEHICLES WITH AUTOMATIC TRANSMISSION .

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

Fig 19: Guide Pin & Adapter T40058

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

-- To loosen the bolts for the torque converter, counterhold the crankshaft at the drive plate using the :T40058 and the offset open-end wrench.

Fig 20: Counter Hold Crankshaft Using Socket T40058

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NOTE:

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

Instead of the :T40058 , the engine can also be rotated with the following tools:

:T40257
:T40263
:T40314

-- Connect the tools as shown.

Fig 21: Crankshaft Turning Tool, Wrench - 21 MM & Adapter

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Socket 21 mm for ¹ /₂ -Drive

Fig 22: Identifying Wrench - 21 MM T40263

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-- Remove cap -1-.

Fig 23: 6 Torque Converter Bolts -Arrows- And Cap

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-- Remove six torque converter bolts -arrows- in the opening of the removed starter (turn the crankshaft a ¹ /₃ rotation in the direction of engine rotation).

NOTE:

Loosen and tighten the torque converter bolts -arrows- on the drive plate -2- with a Torx 55 socket (100 mm long). Do not allow the bolts to fall into the transmission housing.

Replace the bolts after removing them.

-- Remove the top engine/transmission bolts -4 through 6- and the bottom bolts -8 through 10-. Bolts -3 and 7- remain screwed in.

Fig 24: Bolt Removal Sequence

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-- Place the :VAS6931 with the Universal Support on the bottom of the transmission. Place a wooden block between the transmission fluid pan and the Universal Support.

Fig 25: Engine-/Gearbox Jack V.A.G 1383 A With The Universal Support V.A.G 1359/2

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Secure the transmission with the :T10038 to the Universal Support.

-- Slightly relieve the pressure at the top of the engine and transmission using the engine support. Use the :VAS5085 to do this.

-- Remove the remaining engine/transmission bolts -3 and 7-.

-- Dismount the transmission from the engine, and press the torque converter off of the drive plate.

NOTE:

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

-- Lower the transmission using the :VAS6931 . The Transmission Fluid Auxiliary Hydraulic Pump 2 -V476- -1- (if equipped) must not touch the subframe -2- -arrow- during this.

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

Fig 26: Identifying Bracket -30-211A- Attached To Secure Torque Converter

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