Transmission, Removing
Short Description:
The transmission is remove downward by itself.
From above:
The battery, air filter cover and starter are removed. The coolant hoses are clamped off. The transmission mount is removed and the engine and transmission are supported.
From underneath:
The subframe, with the pendulum support, the steering gear and both control arms are removed together.
To remove the subframe, refer to Removal and Installation . 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. This way, the subframe can be secured and removed correctly.
The locating pins -T10096- will be needed.
If the subframe is not secured by the pins, then an axle alignment will be necessary later.
In this case, an axle alignment is unnecessary. It would be a lot of work and an unnecessary charge.
Special tools and workshop equipment required
- Engine Support Bridge 10-222 A
- Adjustment Plate -3282/42A-
- Adapter 10-222 A/13
- Hose Clamps up to 40 mm -3093-, if not available, use Hose Clamps up to 25 mm Dia. -3094-
- Transmission Support -3282-
- Insert Tool 18 mm -T10179-
- Pin -3282/29-
- Adjustment Plate -3282/59-
- Engine-/Gearbox Jack -V.A.G 1383 A-
- Tensioning Straps -T10038-
- Bracket with Spindle and Hook 10-222 A/10
Removing
-- Lift the vehicle, all 4 lift points of the hoist must be at the same height.
-- Move the selector lever into the "P" position.
Do not lower the vehicle onto the floor after loosening the drive axle bolt.
-- Press the brake pedal in order to remove the left drive axle bolts -arrow- (second technician required).
-- Remove the engine cover/upper air filter housing. Refer to [For engine(s) BPY] Removal and Installation , or [For engine(s) CCTA, CBFA] Removal and Installation .
-- Remove the battery, the battery tray bolts -arrows- and tray.
-- Remove the starter. Refer to Removal and Installation .
-- Remove the selector lever cable from the transmission.
Use pliers to remove the lock washer on the cable bracket. Do not use a sharpened lever otherwise the rubber grommet on the cable may get damaged.
Both lock washers -arrows- must later be replaced when adjusting the cable.
Remove the cable from the transmission cable bracket. Do not bend the cable.
You can also slide the cable back slightly from the cable bracket and remove it later when lowering the transmission. Watch the cable when lowering transmission.
Later, install the small lock washer only after having checked and adjusted the cable. Refer to SELECTOR LEVER CABLE, CHECKING .
-- Clamp off the coolant hoses to the cooler using the hose clamps up to 40 mm -3093- or the hose clamps up to 25 mm dia. -3094- and remove the hoses.
-- Remove the wire bracket from the large transmission cover (quantity: 2 M6 nuts).
-- Release the Mechatronic connector retainer by rotating and remove connector.
-- Remove all upper engine/transmission bolts. Insert tool 18 mm -T10179- is especially good for this.
-- Remove the filler pieces from both fender upper edges.
-- Disconnect any hoses and wires in the area of the lifting eye on the engine.
-- Support the engine and transmission using the engine support bridge 10-222 A, the bracket with spindle and hook 10-222 A/10 and the adapter 10-222 A/13. Do not lift up yet.
-- Remove the transmission mount to transmission mount bracket bolts -2- and the transmission mount bracket -A- to transmission mount bolts -1-.
-- Then, lower the engine/transmission slightly using the engine support bridge 10-222 A spindle so the bracket can be removed.
Remove the bracket -arrow-.
-- Remove the noise insulation and lower section of the left front wheel housing liner if necessary. For the noise insulation, refer to Description and Operation , for the wheel housing liner, refer to FRONT WHEEL HOUSING LINER .
-- Remove the drive axle from the transmission and carefully move it to the side.
Do not damage the surface of the drive axles. For this reason, tie straps made out of plastic or both tensioning straps -T10038- are very good to use.
You can remove the left drive axle if you also remove the subframe.
Remove the subframe. Refer to Removal and Installation .
When removing the subframe 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. This way, the subframe can be secured and removed correctly.
-- A small, additional cover plate (above the right axle flange) is located on the engine/transmission intermediate plate. Remove the cover plate -A-.
-- Align the transmission support -3282- with the adjustment plate -3282/42A.
-- Guide the engine-/gearbox jack -V.A.G 1383 A- under the transmission and support it. Do not lift up yet.
The transmission is disconnected from the engine in this position.
-- Remove all remaining engine/transmission bolts.
-- Separate the transmission from the engine while being careful of the selector lever cable and lower the transmission.
Transport the transmission and secure it to the assembly stand. Refer to TRANSMISSION, TRANSPORTING AND SECURING TO THE ASSEMBLY STAND .
Install the transmission. Refer to TRANSMISSION, INSTALLING .
Short Description:
The transmission is remove downward by itself.
From above:
The air filter housing and starter are removed. Also the wiring harness, which comes from the bottom of the subframe, is disconnected so that the subframe can be removed later. The coolant hoses are clamped off. The transmission mount is removed and the engine and transmission are supported.
From underneath:
The subframe is removed with the pendulum support, both control arms and the steering gear.
When removing the subframe. Refer to [For engine(s) BGP, BPY, AWP, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation . 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. This way, the subframe can be secured and removed correctly.
If the subframe is not secured, then an axle alignment will be necessary.
After the subframe is removed, the engine and transmission are supported and the transmission mount bracket is disconnected. The last bolt between the engine and transmission is removed and the transmission is lowered.
Special tools and workshop equipment required
- Engine Support Bridge 10 - 222 A
- Bracket with Spindle and Hook 10 - 222 A/10
- Hose Clamps up to 40 mm -3093-, if not available, use Hose Clamps up to 25 mm Dia. -3094-
- Ball Joint Puller -3287 A-
- Insert Tool 18 mm -T10179-
- Locating Pins -T10096-
- Assembly Tool -T10071-
- Bracket -T10338-
- Adjustment Plate -3282/42A-
- Adapter 10-222 A/18
- Tensioning Straps -T10038-
Removing
-- Lift the vehicle, all 4 lift points of the hoist must be at the same height.
-- Move the selector lever into the "P" position.
-- Disconnect the battery. Refer to [For engine(s) BGP, BPY, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation .
Do not lower the vehicle onto the floor after loosening the drive axle bolt.
-- Press the brake pedal in order to remove the left drive axle bolt -arrow- (second technician required).
-- Remove the air filter housing and the bracket underneath it. Refer to [For engine(s) BPY] Description and Operation , or [For engine(s) CCTA, CBFA] Description and Operation .
-- Remove the starter. Refer to [For engine(s) BGP, BPY, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation .
-- Remove the selector lever cable from the transmission.
Use pliers to remove the lock washer on the cable bracket. Do not use a sharpened lever otherwise the rubber grommet on the cable may get damaged.
Both lock washers -arrows- must later be replaced when adjusting the cable.
Remove the cable from the transmission cable bracket. Do not bend the cable.
You can also slide the cable back slightly from the cable bracket and remove it later when lowering the transmission. Watch the cable when lowering the transmission.
Later, install the small lock washer only after having checked and adjusted the cable. Refer to SELECTOR LEVER CABLE, CHECKING .
-- Clamp off the coolant hoses to the cooler using either the hose clamps up to 40 mm -3093 or the hose clamps up to 25 mm dia. -3094- and remove the hoses.
-- Release the Mechatronic connector retainer by rotating and remove connector.
-- Remove the wire bracket from the large transmission cover (quantity: 2 M6 nuts).
-- Disconnect the wiring harness from the subframe from underneath.
-- Remove the nut -1- and the cable from the E-box.
-- Remove the nut -arrow- and the ground wire -2-.
-- Disconnect the connector -3-.
This wiring harness will be removed later with the subframe. This way, you avoid time consuming work on the steering and heat shield.
-- Disconnect the steering gear from the steering column. Refer to [For engine(s) BGP, BPY, AWP, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation .
Always move the steering wheel into the center position beforehand. Engage the steering wheel lock. Information regarding tightening the bolts is also contained here.
-- Remove all upper engine/transmission bolts. Insert tool 18 mm -T10179- is especially good for this.
It is advisable to complete the work under the vehicle now. This prevents the weight of the engine from resting on the engine support bridge and therefore on the body for a long period of time.
-- Remove the noise insulation and lower section of the left front wheel housing liner if necessary. For the noise insulation, refer to Description and Operation . For the wheel housing liner, refer to FRONT WHEEL HOUSING LINER .
The subframe and the pendulum support will be removed together with both control arms and the steering gear.
When removing the subframe, refer to [For engine(s) BGP, BPY, AWP, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation . 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. This way, the subframe can be secured and removed correctly.
If the subframe is not secured, then an axle alignment will be necessary.
Secure the subframe. Refer to [For engine(s) BGP, BPY, AWP, BGQ, CBTA, CBUA, CCTA, CBFA] Description and Operation >
Remove the subframe.
-- Begin by removing the ball joint to control arm nuts -arrows- on both sides.
-- Disconnect the connector from the left front level control system sensor -G78-.
-- Remove both coupling rods from the stabilizer bar.
-- Separate the tie rod ends from the wheel bearing housings.
-- Remove the exhaust system suspended mount bolts -1- from the subframe.
-- Remove the pendulum support to transmission bolts -4-.
Before removing the bolts -2 through 5- on both sides, install the locating pins -T10096- and support the subframe using the engine/transmission jack -V.A.G 1383 A-.
-- Remove the bolts -2- on both the left and right sides only after you have supported the subframe.
Install a locating pin -T10096- in place of the bolt -2- on both the left and right sides as soon as the bolt is removed.
Do this with bolt -5- too.
If the subframe is not secured, then an axle alignment will be necessary.
It, s important to remove the bolt -1- and install a locating pin -2- immediately.
-- Carefully lower the subframe, be careful of the wiring harness to the engine compartment.
Set the subframe aside.
-- Remove the right drive axle heat shield.
-- Remove both drive axles from the transmission and carefully lay aside.
-- Remove the left drive axle from the vehicle.
Do not damage the surface of the drive axles. For this reason, tie straps made out of plastic or both tensioning straps -T10038- are very good to use.
-- Remove the driveshaft from transmission.
The seal -arrow- in the driveshaft must not be damaged.
-- Install the assembly tool -T10071- with a cloth. This protects the seal.
-- Remove the bracket bolts -1 and 2- and the bracket -A- from between the cylinder block and the bevel box.
-- If necessary, remove the secondary air injection pump motor bracket with the pump and lay it aside.
-- Now, remove all the bolts except for one from the engine/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 wires in the area of the lifting eye on the engine.
-- Support the engine and the transmission using the engine support bridge 10-222 A and bracket with spindle and hook 10-222 A/10. Do not lift up yet.
-- Move the long spindle forward onto the adapter 10-222 A/18.
-- Remove the transmission mount to transmission mount bracket bolts -2- and the transmission mount bracket -A- to transmission bolts -1-.
-- Then, lower the engine/transmission slightly using the engine support bridge 10-222 A spindle so the bracket -A- can be removed.
Remove the bracket -arrow-.
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 transmission support -3282- with the adjustment plate -3282/42A-.
-- Guide the engine-/gearbox jack -V.A.G 1383 A- under the transmission and support it. Do not lift up yet.
The transmission is disconnected from the engine in this position.
-- Remove all remaining engine/transmission bolts.
-- Separate the transmission from the engine while being careful of the selector lever cable and lower it.
Transport the transmission and secure it to the assembly stand. Refer to TRANSMISSION, TRANSPORTING AND SECURING TO THE ASSEMBLY STAND .
Install the transmission. Refer to TRANSMISSION, INSTALLING .