Transmission, Removing

WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. However, it is still accessible from the selected car via links, so may be relevant.

-- If possible, before removing print out a diagnostic protocol for the vehicle. Affix the protocol to the transmission before sending back the removed transmission.

Short Description:

The transmission is remove downward by itself. The engine remains in the vehicle.

Remove the battery housing, the air filter and the engine cover. The engine with transmission are then supported so that the transmission mount can be removed.

Remove the noise insulation and the drive axles from underneath. Lower the transmission with the transmission jack.

NOTE:

The subframe is not removed.

Special tools and workshop equipment required

Engine-/GearboxJjackV.A.G 1383 A
Socket SW15V/175
Transmission Support 3282
Wedge Tool T10161
Torque Wrench (40-200 Nm) V.A.G 1332
Adjusting Plate 3282/36
Engine Support Bridge 10-222 A
Engine Support Feet 10-222 A/8
Adapter 10-222 A/7
Bracket with Spindle and Hook 10-222 A/10
Engine Support Adapter 10-222 A/3
Shackle 10-222 A/12
Hose Clip Pliers V.A.G 1921

Removing

-- Before removing, if possible, print out the diagnostic protocol for the vehicle. Affix the protocol to transmission before sending back the removed transmission in the usual way.

-- Move the selector lever into the "P" position.

-- Lift the vehicle, all 4 lift points of the hoist are at the same height.

-- Push the brake in order to remove the left drive axle bolt -arrow- (second technician required).

Fig 1: Left Front Drive Axle Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Do not set the vehicle on the floor. Refer to Removal and Installation .

-- Remove the engine cover/upper air filter section.

-- Disconnect the hoses -arrows- and remove the intake tube from the throttle valve.

Fig 2: Identifying Intake Hose And Throttle Valve Unit

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-- Remove the battery and battery housing. Refer to Removal and Installation .

-- Disconnect the selector lever cable -1- from the cable bracket -2- and remove it.

Fig 3: Identifying Cable Disengaged And Removed From Mounting Bracket

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Be careful not to bend the cable. Do not use pliers, otherwise the tabs on the cable bracket may break off.

-- Pry the cable -1- off the lever -3- using a open-end wrench -2-.

Fig 4: Prying Selector Lever Cable From Lever/Selector Shaft Using A 10 mm Open-End Wrench

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-- Disconnect the connectors from the transmission and starter.

Multifunction transmission range switch
Starter
Ground cable from the transmission mount bracket

-- Remove the wire bracket -1- from the starter stud bolt -arrow-.

Fig 5: Identifying Harness Retainer From Starter Bolt

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-- Remove the upper bolt from the starter.

-- Remove the upper engine transmission bolts.

So that engine and transmission can be supported:

-- Remove the lines -1- from the transport strap -3-.

Fig 6: Identifying Wires, Engine And Transport Strap

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-- Remove the transport strap -3- from the engine -2- and pull it out of the lifting eye -arrow-.

Fig 7: Identifying Wires, Engine And Transport Strap

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-- Attach one shackle 10-222 A/12 to this lifting eye.

-- Install the engine support bridge 10-222 A.

Fig 8: Engine Support 10 - 222 Installed

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-- Extend the right bracket with spindle and hook 10-222 A/10 with the adapter 10-222 A/7.

The hook points downward and will be engaged on the cylinder block later.

-- Remove the noise insulation.

-- Remove the lower section of the left wheel housing liner.

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

Fig 9: Removing Right Drive Axle Heat Shield Bolts & Shield

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-- Remove the ball joint to lower control arm nuts -arrows- both sides.

Fig 10: Ball Joint To Lower Control Arm Nuts

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-- Remove both drive axles from the transmission. Refer to: Removal and Installation .

-- Remove the left drive axle.

-- Lift the right drive axle as far as possible and then tie it up.

Fig 11: Securing Right Drive Axle

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

Fig 12: Identifying Electrical Connectors At Transmission

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-- Remove the connector -1- from the bracket under the starter and then disconnect it.

Fig 13: Identifying Connector Under Starter

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-- Remove the bracket from the starter lower bolt.

-- Remove the lower bolt from the starter and then remove the starter.

-- Remove the pendulum support, first remove bolt -A-, and then bolts -B-.

Fig 14: Identifying Pendulum Support And Bolts

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-- Drain the coolant.

-- Turn the cap -1- in the -direction of the arrow- and remove it.

Fig 15: Rotating Cover Cap

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-- Remove the six torque converter nuts -arrow- using the socket SW15V/175.

Fig 16: Locating Converter Nuts

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NOTE:

Carefully rotate the engine further!

-- Engage the adapter 10-222 A/7 to the cylinder block.

Fig 17: Adapter 10 - 222 A /7 Engaged On Engine Block

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-- Remove the coolant hoses from the transmission fluid cooler.

Tension the right spindle one turn (more turns are not necessary).

-- Support the engine and transmission with the left spindle. Do not lift it.

-- Remove the transmission mount bracket -A-.

Fig 18: Identifying Left Assembly Mounting Console

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-- Turn the left spindle on the engine support bridge 10-222 A and slightly lower the engine and transmission.

Six turns is sufficient.

-- Remove the lower bolts between the engine and the transmission.

-- Leave one easily accessible bolt for safety.

-- Support the transmission with the engine-/gearbox jack V.A.G 1383 A, the transmission support 3282 and theadjusting plate 3282/36 before removing the last bolt.

-- Remove the last bolt.

-- Separate the transmission from the engine.

NOTE:

Pay attention to the torque converter. It must be removed together with the transmission.

-- The cable bracket and the selector lever cable bracket must be replaced when installing a new transmission.

Fig 19: Identifying Mounting Bracket And Bracket For Selector Lever Cable

Courtesy of VOLKSWAGEN UNITED STATES, INC.