Transmission, Removing, Vehicles With 3.0L TDI BITURBO Engine

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Fig 1: Special Tools And Workshop Equipment

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Special tools and workshop equipment required

Pry lever 80-200
Engine and Gearbox Jack VAS6931
Engine Bung Set VAS6122
Crankshaft Socket T40058
Gearbox Support T40173
M8 x 20 bolt

Warning message!

Fig 2: Gearbox Support T40173 (New Version Has Chrome Plated Parts)

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WARNING:

Before using the Gearbox Support T40173 always check if it meets the requirements.

The older version mounts, should not be used and should be replaced.

Characteristics (Newer Version)

On the newer version the components illustrated -red- are -yellow - chrome plated.

If the mount does not comply with corresponding specifications, proceed as follows:

Market Germany: Contact the company Matra for an exchange.
Markets (word wide except Germany): Contact your tool supplier for an exchange.

Preparing the Gearbox Support T40173:

Fig 3: Bracket Attached To -1- Must Be Removed

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-- The bracket attached to -item 1- must be removed.

-- The bracket -item 2- must be turned so that the longer side faces up as illustrated.

Removing

Fig 4: Disconnecting Battery

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-- Position the front wheels so they are straight.

CAUTION:

Risk of damaging electronic components when disconnecting the battery.

Complete the steps for disconnecting the battery.

-- Disconnect the battery ground cable -2-, refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the engine cover -arrows-.

Fig 5: Removing Engine Cover

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-- Remove the plenum chamber bulkhead, refer to OVERVIEW - BULKHEAD .

-- Remove the catalytic converter.

-- Drain the coolant .

-- Remove the front wheels.

Fig 6: Driveshaft Cover -1-

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-- Remove the left and right driveshaft cover -1- inside the wheel housing.

-- Remove the left and right bolts -arrows- and the heat shield -1-.

Fig 7: Locating Left Bolts & Heat Shield

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NOTE:

Check the vehicle data label or the designation on the rear final drive itself to determine which one is installed in the vehicle. Then select the correct rear final drive repair information.

Fig 8: Counter Hold Using Counterhold Tool T10172 And Adapters T10172/5

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-- Remove the driveshaft, refer OVERVIEW - DRIVESHAFT and DRIVESHAFT, REMOVING AND INSTALLING . .

-- Remove the ATF cooler, refer to ATF COOLER, REMOVING AND INSTALLING .

NOTE:

Use a cloth to catch any leaking coolant.

Fig 9: Heater Core Hoses

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-- Loosen hose clamps -2, and 3- and remove the Coolant Hose -1, and 4- from the Heater Core.

NOTE:

Ignore Hose Clamps - Up To 25mm 3094.

-- Disconnect electrical connectors -1 through 4- and move the wiring harness to the side.

Fig 10: Identifying Connectors

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-- Remove the bolts -arrows- and then remove the air guide pipe -1-.

Fig 11: Identifying Bolts And Pipe

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-- Disconnect the connector -2-.

Fig 12: Differential Pressure Sensor - G505- Component Location

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NOTE:

Ignore -items 1 and 3-.

-- Disconnect the connector -2-.

Fig 13: Identifying Bolt -3-

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-- Remove the bolt -3-, and remove the bracket with Exhaust Gas Temperature Sensor 3 -G495- and Differential Pressure Sensor -G505-.

NOTE:

Ignore -item 1- and -arrow-.

-- Remove the left and right bolt -1-

Fig 14: Identifying Brace & Bolts

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-- Loosen the left and right bolt -3- from the bracket -2- for the turbocharger bracket.

-- Remove the bolts -4, 5- connecting the engine to transmission. They are accessible from above.

Fig 15: Engine to Transmission Bolts And Alignment Sleeves -A-

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NOTE:

Catch any leaking ATF with a cloth.

Fig 16: Identifying ATF Pipe And Bolts

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-- Remove the bolts -arrows- and remove the ATF pipe -1- from the transmission.

-- Seal the open lines and connections with clean plugs from the Engine Bung Set VAS6122.

Fig 17: Identifying Transmission Connector

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CAUTION:

There is a risk of destroying the transmission control module (Mechatronic) with electrostatic discharge.

Do not touch contacts in transmission connector with hands.

-- To discharge static electricity, touch the transmission housing (without wearing gloves).

-- Disconnect the connector on transmission by rotating screw connections counter-clockwise -arrow-.

-- Free up the wiring harness on the transmission.

-- Slide the retainer toward the rear -arrow- and press down the release in order to disconnect the connector -2- for the steering gear.

Fig 18: Identifying Connector

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-- Free up the wiring harness.

NOTE:

Ignore -item 1-.

-- Remove the ball socket -1- on the selector lever cable from the selector shaft lever using the Pry Lever 80-200.

Fig 19: Ball Socket And Securing Clips

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-- Press the securing clips -2- off and remove the selector lever cable from the transmission.

NOTE:

Do not bend or kink the selector lever cable.

-- Remove the bolts -arrows- and then remove the heat shield from the right driveshaft.

Fig 20: Drive Axle Heat Shield & Bolts

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-- Remove the bolts -arrows- and the left driveshaft heat shield.

Fig 21: Identifying Bolts And Left Drive Axle Heat Shield

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-- Remove the left and right driveshafts from the transmission flange shafts, refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Remove the lower cover -1- from the transmission -arrow-.

Fig 22: Identifying Transmission Lower Cover

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-- Insert the Crankshaft Socket T40058 guide pins as follows:

Fig 23: 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 torque converter by the crankshaft drive plate using the Crankshaft Socket T40058 when loosening the bolt.

Fig 24: Counter Holding Crankshaft Using Crankshaft Socket T40058

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NOTE:

When mounting, turn the crankshaft only in the direction of engine rotation -arrow-.

-- Remove the six torque converter bolts -arrow- while turning the crankshaft 60° further in the direction of engine rotation.

Fig 25: Identifying Clutch Module First Bolt Installation Location

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-- Remove the bolt -arrow 1- from the starter.

Fig 26: Locating Starter Bolt & Locking Piece

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-- Remove the starter -A- from the transmission.

-- Remove the engine/transmission connecting bolt -arrow 2-.

NOTE:

Locking Ring -B- can fall out after loosening the starter.

-- Remove the remaining engine/transmission bolts -3, 6, 8, 9, and 10- but leave one bolt -7- installed hand-tight.

Fig 27: Engine to Transmission Bolts And Alignment Sleeves -A-

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CAUTION:

Danger of leaks in the ATF pan.

The Gearbox Support T40173 must not be set on the ATF pan.

-- Place the Engine/Gearbox Jack VAG1383A with the preparedGearbox Support T40173 on the bottom of the transmission.

-- The transmission support must be placed at the front as follows:

Fig 28: Positioning Transmission Mount To Transmission Housing

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The bracket -2- fits into the dual-mass flywheel on the transmission housing on the left side of the transmission.
The transmission mount is positioned on the differential housing on the right side of the transmission. Insert a flat piece of rubber -1- in between to protect the housing.

-- Secure the transmission with a tensioning strap -1-.

Fig 29: Securing Transmission With A Tensioning Strap

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NOTE:

The Gearbox Support T40173 is not illustrated.

Fig 30: Identifying Crossmember & Bolts

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-- Remove the bolts from the tunnel crossmember -arrows-.

-- Remove the last bolt from the transmission to engine connection.

Fig 31: Securing Transmission With A Tensioning Strap

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-- Press the transmission off the engine and lower it carefully using the Engine/Gearbox Jack VAG1383A.