Transmission, Removing

WARNING: This page is about a different car, the 2008 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Engine support bridge 10-222A
Bracket with spindle and hook 10-222A/10
Hose clamps up to 25 mm dia.3094 or Hose clamps up to 40 mm3093
Ball joint puller 3287A
Insert tool 18 mm T10179
Locating pins T10096
Adapter 10-222A/18
Tensioning strap T10038
Socket and key T10061
Assembly tool T10071
Bracket T10338
Transmission support 3282
Adjustment plate 3282/42A
Engine and transmission jack VAG 1383A

-- Before removing, print out a diagnostic protocol for this vehicle. Before sending the transmission back in the usual manner, secure this protocol to the transmission so that it is not lost during transportation.

Short Description

The transmission is removed downward as a unit.

From above:

The air filter and starter are removed. also the wiring harness, which comes from the bottom of the subframe, is disconnected so that subframe can be removed later. Coolant hoses are clamped off and the engine/transmission is supported before the left transmission mount bracket is removed.

From below:

the subframe is removed together with the pendulum support, both control arms and steering gear.

Fig 1: Identifying Subframe Secured On Engine/Transmission Jack V.A.G 1383 A With Accompanying Strap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

For removing the subframe refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) BGP, BPY, AWP, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation . There is much useful information there. If done correctly, the subframe can be removed and installed without the customer experiencing increased tire wear later. It is recommended to read this information before removing the transmission. In this way, the subframe can be secured and removed correctly.

If the subframe is not secured, you must perform a vehicle alignment later.

After the subframe is removed, the engine/transmission are supported and the left transmission bracket is disconnected. The last bolt between the engine and transmission is removed and transmission is lowered.

Removing

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

-- Place selector lever in the >>P<< position.

NOTE:

Do not place the vehicle on the floor after loosening the drive axle bolt.

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

Fig 2: Identifying Left Drive Axle Bolt

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-- Disconnect the battery. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) BGP, BPY, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation .

-- Remove the entire air filter housing. Refer to AIR FILTER ASSEMBLY OVERVIEW .

Fig 3: Subframe

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Later, when installing the transmission, it is possible to make sure the transmission ventilation cap fits properly.

-- Disconnect the ground cable from the air filter housing bracket and remove the bracket bolts and bracket.

-- Remove the starter. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) BGP, BPY, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation .

It is advisable to remove the lower starter bolt first.

CAUTION:

Do not use any tools with points or sharp edges to remove the retaining washers.

The boot could get damaged.

-- Remove the selector lever cable from the transmission.

Fig 4: Identifying Lock Washers

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Both lock washers must later be replaced when the adjusting cable.

Remove the cable from the transmission mount bracket with great care. Do not bend.

You can also slide the cable back slightly from the bracket and later remove when the lowering transmission. But then observe the cable when lowering the transmission.

During later installation, only engage new lock washers after you have checked and adjusted the cable. Refer to SELECTOR LEVER CABLE, CHECKING .

-- Clamp off the coolant hoses using the 3093/3094 and remove disconnect them.

Fig 5: Identifying Coolant Hoses Clamped Using Clamps 3094

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-- Disconnect the mechatronic connector retainer by rotating and remove the connector.

-- Remove the cable bracket from the black front transmission cover (2 M6 nuts).

-- Disconnect the wiring harness that comes from the bottom of the subframe.

Fig 6: Identifying Wiring Harness And Brackets On Longmember

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-- Remove the nut -1- and remove the cable from the E-box.

Fig 7: Locating Wire In E-Box

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-- Remove the nut and remove the ground cable -2- from the stud -arrow-.

Fig 8: Identifying Ground Cable And Connector

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-- Disconnect the electrical connector -3-.

This wiring harness is removed later with the subframe. In this way, you avoid time consuming work on the steering and heat shield.

-- Disconnect the steering column from the steering gear.

Fig 9: Identifying Footwell Trim And Nuts

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Check once in the steering gear removal procedure, refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) BGP, BPY, AWP, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation for what should be considered when doing so.

Always move the steering wheel into the center position beforehand. Engage the steering wheel lock. Information regarding tightening the bolts is also contained there.

-- Then remove all upper engine/transmission bolts.

Use the following tools:

T10061
T10035
T10179

It is advisable to complete the work under the vehicle now. This prevents the weight of the engine from weighing on the engine support bridge for a long period of time.

-- Remove the noise insulation. Refer to Description and Operation .

-- Remove the lower part of the front left wheel housing liner. Refer to FRONT WHEEL HOUSING LINER .

Remove the subframe together with the pendulum support, both control arms and steering gear.

Fig 10: Identifying Subframe Secured On Engine/Transmission Jack V.A.G 1383 A With Accompanying Strap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

For the subframe removal, refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) BGP, BPY, AWP, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation . There is much useful information there. If done correctly, the subframe can be removed and installed without the customer experiencing increased tire wear later. It is recommended to read this information prior to removing the transmission. In this way, the subframe can be secured and removed correctly.

If the subframe is not secured, you must perform a vehicle alignment later.

Securing the subframe and brackets. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) BGP, BPY, AWP, BGQ, CBTA, CBUA, CCTA, CBFA] Description and Operation .

Removing the Subframe

-- Begin by removing the ball joint nuts -arrows- on both sides of the lower control arms.

Fig 11: Identifying Lower Control Arm And Bolts

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-- Disconnect the electrical connector for the left front level control system sensor.

-- Remove both coupling rods from the stabilizer bar.

-- Press out both tie rod ends.

Fig 12: Identifying Tie Rod End Pressed Off From Wheel Bearing Housing With Ball Joint Puller 3287A

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-- Remove the pendulum support. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) BGP, BPY, AWP, BGQ, CBTA, CBUA, CCTA, CBFA] Description and Operation .

-- Remove the exhaust system suspended mount bolts -1-.

Fig 13: Removing Bolts On Both Sides Only After You Have Supported Subframe

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-- Remove the pendulum support bolts -4-.

Before removing the bolts -2 through 5- on both sides, remove the T10096 by hand.

Fig 14: Locating Fixture T10096

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Support the subframe using the VAG 1383A.

Fig 15: Engine & Transmission Jack VAG 1383 A

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-- Remove the bolt -2- on both sides only after you have supported the subframe.

Fig 16: Removing Bolts On Both Sides Only After You Have Supported Subframe

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As soon as you have removed the bolt -2-, immediately install a T10096 on both sides.

Do this with bolt -5- also.

If the subframe is not secured, you must perform a vehicle alignment later.

It is important: Remove the bolt -1-, install locating pin -2- immediately.

Fig 17: Caution: After Removing A Bolt, Immediately Install A Locating Pin T10096

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-- Carefully lower the subframe, be careful of the wiring harness to the engine compartment.

Set the subframe aside.

Fig 18: Identifying Subframe Secured On Engine/Transmission Jack V.A.G 1383 A With Accompanying Strap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the heat shield bolts -1- and shield above the right drive axle.

Fig 19: Drive Axle Heat Shield -- All Wheel Drive

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-- Remove both drive axles from the transmission and carefully lay aside.

-- Remove the left drive axle.

The axle shaft surface protection must not be damaged. For this reason, plastic cable ties are good for securing the right drive axle to the vehicle.

The right drive axle can also be secured to the strut with the T10038.

Fig 20: Identifying Ratchet Strap

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-- Remove the driveshaft flexible disc bolts -arrows- from the transmission.

Fig 21: Identifying Bevel Gear Transfer Case Flange Bolts

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The seal in the driveshaft must not be damaged.

Fig 22: Identifying Sealing Ring In Driveshaft Flange

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-- Clamp the T10071 with a cloth. This protects the seal.

Fig 23: Clamping Assembly Fixture T10071 With Cloth

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-- Remove the retaining plate -A- between the engine block and bevel box.

Fig 24: Identifying Bracket For Bevel Box & Bolts

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Remove the nuts -1- first.

When installing, first hand tighten all the bolts. Then tighten the bolts -2-.

Tightening specification: 40 Nm

-- Remove the countersunk bolt using T10107A.

Fig 25: Removing The Countersunk Bolt Using T10107A

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The flange shaft remains in the transmission.

-- Disconnect the bevel box from the transmission and remove it.

While removing the bevel box, a second technician must be pushing the engine forward.

-- If necessary, remove the bracket with secondary pump and lay the pump aside.

-- Now remove all bolts except one between the engine and transmission.

It is advisable to leave a bolt that is easily accessible.

-- Remove the filler pieces from both fender upper edges.

-- Disconnect any hoses and cables in the area of the 10-222A lifting eye on the engine.

-- Support the engine and transmission using the 10-222A and the 10-222A/10. Do not lift up.

Fig 26: Supporting Engine And Transmission With Engine Support Bridge 10 - 222 A, Adapter 10 - 222 A/3, Hooks 10 - 222 A/10 And Adapter 10 - 222 A/13 (V6 Engine (R32))

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-- Remove the long spindle on the 10-222A /18 forward.

-- Remove the bolts -1 and 2- to the transmission mount bracket -A-.

Fig 27: Identifying Transmission Support Plate And Bolts

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-- Then lower the engine/transmission slightly using the 10-222A until the bracket -A- can be removed.

Remove the transmission mount bracket in the - direction of the arrow-.

Fig 28: Identifying Transmission Support Plate

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It really only needs to be lowered a little. As soon as the bracket can be removed, this is enough to guide the transmission onto the longitudinal member later. Add a maximum of 4 turns to each spindle.

-- Align the 3282 with the 3282/42 A.

-- Guide the VAG 1383A under the transmission and support the transmission. Do not lift up.

The transmission is disconnected from the engine in this position.

-- Remove all remaining engine/transmission bolts.

-- Remove the transmission from the engine while being careful of the selector lever cable and lower the transmission.

-- You should have permanently attached the transmission's diagnostic protocol for analysis to the transmission ready for shipment.

Transport the transmission and secure it to the assembly stand. Refer to TRANSMISSION, TRANSPORTING AND SECURING ON ASSEMBLY STAND .

Installing the transmission. Refer to TRANSMISSION, INSTALLING .