Transmission, Removing, Diesel Vehicles

WARNING: This page is about a different car, the 2017 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Engine and Gearbox Jack: VAS6931
Transmission Support - Mounting Plate 42A: 3282/42A
Hose Clamps - Up To 25 mm: 3094
Tensioning Strap: T10038
Engine Bung Set: VAS6122
Insert Tool - 18mm: T10179
Engine Support Bridge: 10-222A
Engine Support - Bracket w/Spindle and Hook: 10-222A/10
Engine Support Bridge - Spindle: 10-222A/11
Engine/Gearbox Support Shackle (2 pc.): 10-222A/12
Engine Support Bridge - Engine Support 28: 10-222A/28
Engine Support Bridge - Engine Support 28-1: 10-222A/28-1
Engine Support Bridge - Engine Support 31: 10-222A/31
Engine Support - 1: 10-222A/31-1
Engine Support - 2: 10-222A/31-2
Engine Support - Basic Set: T40091
Engine Support - Basic Set - Square Pipe: T40091/1
Engine Support - Basic Set - Rail with Holes: T40091/2
Engine Support - Joint Fixture: T40091/3
Engine Support - Supplement Kit: T40093A
Engine Support Supplement Set - Movable Joint: T40093/4
Engine Support Supplement Set - Mount: T40093/5
Transmission Support: 3282
Transmission Support - Pins 29: 3282/29
Transmission Support - Mounting Plate 42A: 3282/42A
Socket - Xzn 14: T10061
Transportation Lock: T10404

Removing

-- Move the selector lever to >>P<<.

Fig 1: Identifying Selector Lever In "P" Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING (CPLA, CPPA, CPKA, CPRA) .

-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Remove the battery. Refer to BATTERY, REMOVING AND INSTALLING .

-- Remove the battery tray. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

Fig 2: Identifying Battery Housing Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the selector lever cable from the transmission -arrows-.

Fig 3: Identifying Lock Washers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Use pliers to remove the lock washer from the cable bracket. Do not use a sharp-edged lever. Otherwise the selector lever cable could get damaged.

CAUTION:

Risk of damaging the selector lever cable.

Remove the selector level cable from the cable bracket when lowering transmission.
Do not bend or kink the selector lever cable.

-- Remove the charge air pipe. Refer to OVERVIEW - CHARGE AIR SYSTEM .

-- Place a lint-free cloth on to transmission fluid cooler and transmission to absorb escaping coolant.

NOTE:

The cooling system is under pressure when the engine is warm.

Cover the cap on the coolant expansion tank with a cloth and open it carefully before removing the coolant hoses.

-- Clamp off the coolant hoses using the : 3094 and remove the hoses from the transmission fluid cooler.

Fig 4: Clamping Off Coolant Hoses Using Clamps 3094

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Seal off the transmission fluid cooler connections with suitable sealing plugs taken from the : VAS6122 .

-- Release the connector twist lock -1- for the Mechatronic by turning it in the direction of the starter and remove the connector.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the starter. Refer to STARTER, REMOVING AND INSTALLING .

Remove the >>lower<< bolt first.

CAUTION:

There is a risk of damaging the DSG Transmission Mechatronic -J743- with static electricity.

Do not touch contacts in DSG Transmission Mechatronic -J743- connector with hands.

-- To discharge any static electricity, touch the vehicle ground with hand (without wearing a glove). Refer to Electrical Components .

-- Remove all upper engine/transmission connecting bolts.

Fig 5: Identifying Special Tool T10179

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

One bolt is located inside the hole for the starter -arrow-. Use : T10061 to remove the bolt.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Remove the lock carrier trim. Refer to OVERVIEW - LOCK CARRIER .

-- Disconnect any hose- and cable connections near the engine lifting eyes for the : 10-222A .

-- Remove the bolts -arrows- for the left and right lock carrier retaining brackets.

Fig 6: Identifying Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the lower mounts on the : 10-222A/28 and replace with the : 10-222A/28-1 .

Fig 7: Identifying Engine Support Bridge Engine Support

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Position the : 10-222A/28 with the : 10-222A/28-1 on the left and right side of the lock carrier and install in the threaded holes on the lock carrier retaining brackets -arrows-.

Fig 8: Identifying Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Use the existing bolts in the : 10-222A/28 for attaching the : 10-222A/28-1 . Do not use the bolts for the retaining bracket. Refer to TRANSMISSION, REMOVING, DIESEL VEHICLES - Remove the bolts -arrows- for the left and right lock carrier retaining brackets. .
Bolt tightening specification -arrows- : 8 Nm

CAUTION:

A second technician is required to mount the : 10-222AA on the vehicle to prevent the : 10-222AA from tipping.

To support the engine/transmission assembly, mount the engine support bridge as follows:

Fig 9: Identifying Engine Support Bridge

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

: 10-222A/31-2
: T40091/3
: 10-222A/31-1
: T40093/4
: T40091/1
: 10-222A/28 with : 10-222A/28-1
: 10-222A/10

-- First slide the Moveable Joints -2- onto the Square Pipe of the : 10-222A .

The bolts for the : T40091/3 -2- on the : 10-222A face toward the front of the vehicle.

-- Mount the : 10-222A on the suspension strut towers and have a second technician hold it to prevent it from tipping.

-- Push the left and right : T40091/1 - 5- from the front through the : 10-222A/28 - 6- and position the : T40093/4 - 4- on each side.

-- Additionally attach the : 10-222A/10 - 7- on the left : T40091/1 .

Fig 10: Identifying Engine Support Bridge

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

: 10-222A/31-2
: T40091/3
: 10-222A/31-1
: T40093/4
Engine Support - Basic Set - Square Pipe: T40091/1
: 10-222A/28 with : 10-222A/28-1
: 10-222A/10
: T40091/2
: T40093/5
: 10-222A/11

-- Slide the : T40091/2 - 8- with the : T40093/5 -9- in the : T40093/4 - 4-.

-- Install the locking pins into the : T40091/2 -8- and secure it with the cotter pins.

-- Hand-tighten all the threaded connections on the Engine Support Bridge. While doing so, adjust the height of the Engine Support Bridge parallel over the : 10-222A/28 .

-- Lightly preload the engine/transmission assembly using the : 10-222A/10 - 7- and : 10-222A/11 - 10-. Do not lift.

-- Loosen left and right front wheel bolts.

-- Raise the vehicle and remove the front wheels.

-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- Remove the left and right front wheel housing liners. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Remove the wires and the bracket from the transmission fluid pan -arrows- (two M6 nuts).

Fig 11: Identifying Nuts And Bracket

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Route the wires near the transmission fluid pan upward and tie them secure.

-- Disconnect the connector -arrow- from the Oil Level Thermal Sensor -G266-, if equipped.

Fig 12: Identifying Connector From Oil Level Thermal Sensor

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the noise insulation -1- for the transmission fluid pan by loosening the fasteners -arrows-.

Fig 13: Identifying Oil Pan Noise Insulation

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

Risk of damaging the decoupling element.

Do not bend the decoupling element more than 10°.
Do not place any load on the decoupling element.
Do not damage the wire mesh on the decoupling element.

-- Disconnect the exhaust system at the clamping sleeve and remove the exhaust system bracket from the subframe -arrows-. Refer to OVERVIEW - EMISSIONS CONTROL (CPLA, CPPA, CPKA, CPRA) .

Fig 14: Identifying Exhaust System Bracket (Suspended Mount) Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tie up the front exhaust pipe.

NOTE:

The decoupling element can also be secured in its installed position using the : T10404 -arrow-.

Fig 15: Identifying Decoupling Element

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolts -11- and then remove the pendulum support from the transmission.

Fig 16: Identifying Pendulum Support Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure the subframe before removing. Refer to SUBFRAME, SECURING .

Fig 17: Identifying Subframe Secured On Engine/Transmission Jack V.A.G 1383 A With Accompanying Strap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

If the -subframe- is not secured, an axle alignment must be performed later.

-- Remove the subframe with the steering gear. Refer to SUBFRAME WITH STEERING GEAR, REMOVING AND INSTALLING .

-- Remove the heat shield above the right drive axle -arrows-.

Fig 18: Drive Axle Heat Shield

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the drive axles from the transmission. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Tie the right drive axle as high up as possible.

Fig 19: Identifying Ratchet Strap On Right Drive Axle

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Move the left drive axle to the rear and secure it. Be careful not to damage the surface protection.

-- There may be a small cover plate on the plate between the engine and transmission above the right flange shaft. If equipped, remove the cover plate -A-.

Fig 20: Flywheel Small Cover Plate Behind Right-Hand Flanged Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolts -1 and 2- from the transmission bracket -A-.

Fig 21: Identifying Transmission Support Plate And Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Slightly lower the engine/transmission assembly using the spindles on the : 10-222A so that the transmission bracket can be removed.

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

Fig 22: Identifying Transmission Support Plate

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

To remove the transmission, the : 3282 is equipped with the : 3282/42A and positioned on the : VAS6931 .

Fig 23: Direct-Shift Gearbox 02E

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Align the arms of the Transmission Support so that they match up with the holes in the : 3282/42A .

-- Install the mounting element as illustrated above on the : 3282/42A .

-- Place the : VAS6931 under the vehicle.

The arrow symbol on the : 3282/42A points in the direction of travel.

-- Align the : 3282 so that it is parallel to the transmission.

-- Install the : 3282/29 in the transmission.

-- Secure both the other support elements to the transmission as shown.

NOTE:

Deviating from the illustration above of the Adjusting Plate the front transmission support is illustrated above mounted to the transmission -arrow-.

The transmission 02E with "AWD" is shown in the illustration above. The mounting elements on the "FWD" are identical.

-- Support the transmission by lifting it from underneath using the : VAS6931 .

The transmission is disconnected from the engine in this position.

-- Remove the remaining engine/transmission connecting bolts.

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

NOTE:

Pay attention to all of the lines when lowering the transmission.

Transmission, transporting. Refer to TRANSMISSION, TRANSPORTING .

Secure the transmission on the assembly stand. Refer to SECURING ON ENGINE AND TRANSMISSION HOLDER .

Install the transmission. Refer to TRANSMISSION, INSTALLING .