Removal And Installation: Transmission: Removing

WARNING: This page is about a different variant/trim than selected.

-- First, check whether a coded radio is installed. If so, obtain the anti-theft code.

-- Turn off the ignition and disconnect the battery ground cable. Refer to Removal and Installation .

Later in the procedure, the engine support bridge 10-222 A is installed to engine lifting eyes.

-- Remove the engine cover if it is blocking the lifting eyes.

-- Remove the air filter housing if it is located near the battery. Refer to [For engine(s) BPY] Removal and Installation [For engine(s) CCTA, CBFA] Removal and Installation .

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

-- Remove the shift cable lock washer -3- from the transmission shift lever -1- and remove the cable from the pin -arrow-.

Fig 1: Removing/Installing Shift Cable Lock Washer From Transmission Shift Lever And Cable From Pins

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With a Metal Relay Lever:

-- Remove the selector cable lock washer -4- from the relay lever -2- and remove the cable from the pin -arrow-.

With a Plastic Relay Lever:

Disconnect the cable retainer from the selector cable.

Fig 2: Disconnecting Cable Retainer From Selector Cable

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To avoid damage to the selector cable, the cable retainer must first be removed from the selector lever.

-- Pull the locking mechanism all the way forward in the -direction of arrow 1- and then unlock it to the left in the -direction of arrow 2-.

-- Press the relay lever forward (in the -direction of arrow 3-).

-- The plastic relay lever is removed together with the cable retainer later in the procedure.

Continuation for all Vehicles:

Fig 3: Removing/Installing Cable Mounting Bracket From Transmission

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-- Remove the cable bracket bolts -arrows- from the transmission, move it to the side and secure it.

Vehicles with a Pipe between the Clutch Master and Slave Cylinders:

Fig 4: Using Hose Clamps 3094 To Clamp Supply Hose To Master Cylinder

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-- Clamp the supply hose to the master cylinder using the hose clamps up to 25 mm dia. 3094.

Vehicles with a Hose/Line Assembly between the Clutch Master and Slave Cylinders:

Fig 5: Clamping Off Hose/Line Assembly Hose To Slave Cylinder With Hose Clamps

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-- Clamp off the hose on the hose/line assembly -A- to the clutch slave cylinder using the hose clamps up to 25 mm dia. 3094.

Continuation for all Vehicles:

-- Pull the clip -arrow- for the hose/line assembly or pipe out to the stop.

-- Remove the hose/line assembly or pipe from the breather assembly/slave cylinder and seal it off.

CAUTION:

Do not press the clutch pedal anymore.

-- Remove the ground strap -1- from the starter upper stud.

Fig 6: Identifying Ground Strap & Back-Up Light Switch F4 Electrical Harness Connector

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-- Disconnect the connector -2- from the backup lamp switch -F4-.

-- Disconnect the connector from the starter.

-- Remove the engine/transmission upper bolts -arrows-.

Fig 7: Removing Bolts At Engine/Transmission Flange

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-- Then, remove the upper bolt for the starter.

-- Remove the left and right foam pieces from the upper fender edge. Refer to Description and Operation .

-- Disconnect any hoses and wires in the area of the lifting eyes on the engine.

Fig 8: Installing Engine Support Bridge 10-222 A With Adapter 10-222 A/13 In Front Of Engine Hood Support

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-- Install the engine support bridge 10-222 A with the adapter 10-222 A/13 in front of the engine hood support.

-- Tension the engine/transmission subassembly slightly using the spindle.

-- Loosen the left and right front wheel bolts.

-- Lift the vehicle.

-- Remove the front wheels.

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

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

-- Remove the left front level control system sensor -G78-, if equipped. Refer to Removal and Installation .

Fig 9: Left Front Level Control System Sensor

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-- Remove the bracket from the starter.

-- Remove the starter. Refer to Removal and Installation .

-- Loosen the clamps -arrows 1 and 2- for the charge air hose and remove the hose.

Fig 10: Disconnecting Connection On Air Duct Pipe Between Charge Air Cooler And Charge Air Pressure Sensor G31 Intake Manifold

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-- Remove the exhaust system suspended mount bolts -arrows- from the subframe.

Fig 11: Removing Bracket For Exhaust System From Subframe

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-- Disconnect the exhaust system at the double clamp -arrows-.

Fig 12: Disconnecting Exhaust System At Double Clamp

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-- Tie up the front exhaust pipe.

-- If present, remove the exhaust system support -1- bolt -arrow- from the transmission and remove the front exhaust pipe.

Fig 13: Identifying Exhaust System Brace

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-- Remove the pendulum support bolts from the transmission.

Fig 14: Transmission Pendulum Support

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-- Remove the left drive axle from the transmission flange shaft.

-- Secure the drive axles. Do not damage the protective coating when doing this.

Remove the right drive axle from the transmission flange shaft -A-.

Fig 15: Guiding Right Flange Shaft In Area Of Flywheel/Intermediate Plate

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-- Remove the drive axle heat shield bolts -arrows- and shield, if equipped.

Fig 16: Drive Axle Heat Shield Bolts And Shield

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-- Secure the drive axle.

-- Remove the left and right coupling rods from the stabilizer bar.

-- Remove the left and right ball joint nuts -arrows- from the control arms.

Fig 17: Control Arm Ball Joint Nuts

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-- Secure the subframe. Refer to Description and Operation .

-- Remove the subframe and pendulum support, the stabilizer bar, the brackets and control arms. Refer to Removal and Installation .

-- Remove the transmission mount to transmission mount bracket bolts -arrows-.

Fig 18: Aligning Engine/Transmission In Installed Location

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-- Adjust the spindles and lower the transmission approximately 60 mm to dimension -a-.

Fig 19: Lowering Transmission To Dimension By Adjusting Spindles

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NOTE:

When moving the engine/transmission assembly, be aware of the coolant hose between the engine and heater core. Do not overstretch them.

-- Remove the transmission mount bracket bolts -arrow- from the transmission and remove the bracket -1-.

Fig 20: Installing Console With New Hex Bolts On To Transmission

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With a Metal Relay Lever:

Fig 21: Inserting Actuator Lever Into Shift Mechanism And Clip In Locking Washer

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-- Remove the lock washer -arrow- from the relay lever -1- and then remove the relay lever.

With a Plastic Relay Lever:

-- Remove the relay lever with the cable retainer. Refer to PLASTIC RELAY LEVER .

Continuation for all Vehicles:

-- Remove the transmission shift lever from the gear shift unit.

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

Fig 22: Removing/Installing Small Cover Plate For Flywheel

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-- Remove the small flywheel cover plate -A-.

-- Remove the lower engine/transmission bolts -2-.

Fig 23: Removing Lower Connecting Bolts For Engine/Transmission

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NOTE:

Loosen the engine/transmission bolt -3- and leave it in so that it is hand-tight.

In order to remove the transmission, the adjustment plate -3282/33- must be installed on the transmission support -3282-.

Fig 24: Installing Support Elements Onto Adjustment Plate

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-- Install the transmission support 3282 to the engine/transmission jack V.A.G 1383 A.

-- Align the arms of the transmission support so that they match up with the holes in the adjustment plate.

-- Install the support elements -A- as illustrated on the adjustment plate.

-- Install the pins 3282/29 in place on the adjustment plate -C-.

-- Position the engine/transmission jack V.A.G 1383 A under the vehicle. The arrow symbol -B- on the adjustment plate points in the direction of travel.

-- Align the adjustment plate so that it is parallel to the transmission.

-- Install the adapter VW 771/40 in the threaded hole in the transmission housing as illustrated.

Fig 25: Inserting Engine/Transmission Connecting Bolt

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-- Install the pin 3282/29 into the hole on the transmission for the pendulum support bolt.

-- Secure the transmission to transmission support 3282 using the bolt -A-.

The arm -B- must be flush -arrow- with the guide on the transmission support 3282.

-- Remove the last engine/transmission bolt -C-.

-- Separate the transmission from the engine (alignment sleeves).

-- Rotate the transmission upward near the differential by adjusting the spindle on the transmission support 3282.

-- Tilt the transmission to the left by adjusting the spindles on the transmission support 3282.

-- Carefully lower the transmission.

NOTE:

Pay close attention to the steering gear when lowering the transmission.

Pay attention to the lines when lowering the transmission.