Transmission, Removing, Vehicles With 3.0L TDI Engine

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Special tools and workshop equipment required

Pry Lever 80 - 200
Engine and Gearbox Jack VAS 6931
Engine Bung Set VAS 6122
Tensioning Strap T10038
Gearbox Support T40173
Crankshaft Turning Tool T40257
Wrench - 21mm T40263
Adapter T40314

Fig 1: 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 2: Bracket Attached To -1- Must Be Removed

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

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

Removing

Fig 3: 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 (GND) cable -2-, refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the engine cover -arrows-.

Fig 4: Removing Engine Cover

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

-- Remove the catalytic converter, exhaust pipe and Selective Catalytic Reduction (SCR) - Catalytic converter, refer to OVERVIEW - MUFFLER .

-- Remove the front wheels.

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

Fig 5: Driveshaft Cover -1-

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

Fig 6: Locating Left Bolts & Heat Shield

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

Fig 7: Drive Axle Heat Shield & Bolts

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

-- Remove the ATF pipe bolts on the engine -arrow 1- and transmission -arrow 2-.

Fig 8: Locating Bolts From ATF Pipe On Engine -1- & Transmission -2-

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NOTE:

Place a clean cloth under the separating point to catch the escaping ATF.

Fig 9: Identifying Bolts And ATF Lines From Transmission

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-- Remove the bolts -1 and 2- and remove the ATF pipes from the transmission, then secure them at the top.

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

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 10: 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 bolts -4 and 5- connecting the engine to transmission. They are accessible from above.

Fig 11: Engine to Transmission Bolts And Alignment Sleeves -A-

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-- Move the tower brace into its installed position and then tighten the bolts hand-tight.

Fig 12: Securing Engine With Tensioning Strap

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-- Secure the engine with the Tensioning Strap T10038 as illustrated.

-- Remove the subframe crossbrace, refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

Fig 13: Locating Power Steering Hydraulic Line

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CAUTION:

The suspension components could be damaged.

Do not rest the vehicle on its wheels if the subframe mount, steering gear or subframe crossbrace are not installed correctly.

-- Remove the steering intermediate shaft from the steering gear and push splines together, refer to OVERVIEW - STEERING COLUMN -item 18-.

Fig 14: Locating Universal Joint Bolt

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Fig 15: Identifying Transmission Connector

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CAUTION:

There is a risk of destroying the Transmission Control Module (TCM) (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.

-- Loosen the retainer -arrow-, push the release downward to disconnect the connector -2- from the Power Steering Control Module -J500-.

Fig 16: Identifying Connector

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-- Disconnect the connector -1- from the Power Steering Control Module -J500-.

-- Free up the wiring harness.

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

Fig 17: Pressing Selector Lever In Cable Ball Socket

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-- Remove the bolts -3- and remove the selector lever cable and cable bracket from the transmission and, if necessary, bind them upward.

NOTE:

Do not bend or kink the selector lever cable.

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

Fig 18: Identifying Transmission Lower Cover

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-- Connect the tools the as illustrated.

Fig 19: Crankshaft Turning Tool, Wrench - 21 MM And Adapter

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Socket 21 mm for ¹ /₂ "-drive

Fig 20: Identifying Wrench - 21 MM T40263

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-- Counterhold the crankshaft to loosen the dual mass flywheel bolts.

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 21: Identifying Clutch Module First Bolt Installation Location

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

Fig 22: 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 23: Engine to Transmission Bolts And Alignment Sleeves -A-

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Fig 24: Positioning Transmission Mount To Transmission Housing

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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 prepared Gearbox Support T40173 on the bottom of the transmission.

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

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 25: Securing Transmission With A Tensioning Strap

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NOTE:

The Gearbox Support T40173 is not illustrated.

Fig 26: 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 27: 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.