Transmission, Removing, Vehicles With Diesel Engine

Special tools and workshop equipment required 

• Engine Support Bridge: 10-222A 
• Engine/Gearbox Support Shackle: 10-222A/12 
• Engine Support - Adapter 1: 10-222A/31-1 
• Engine Support - Adapter 2: 10-222A/31-2 
• Engine Support - Basic Set - Square Pipe: T40091/1 
• Engine Support - Joint Fixture: T40091/3 
• Engine Support Supplement Set - Spindle: T40093/3  from Engine Support Supplement Set: T40093B 
• Transmission Support: 3282 

Special tools and workshop equipment required 

• Engine Support Bridge - Engine Support 29: 10-222A/29 
• Transmission Support - Mounting Plate 33: 3282/33 
• Support Elements for transmission (determine when mounting the Mounting Plate on the Transmission Support)
• Transmission Support Jig: 3336  for transporting the transmission
• Torque Wrench, 6-50Nm: VAG1331A 
• Torque Wrench 1332 40-200Nm: VAG1332 
• Engine and Gearbox Jack: VAS6931 

Special tools and workshop equipment required 

• Engine Support Brackets: T40093/3-6 
  Fig 3: Identifying Engine Support Brackets

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• Slide Hammer Set - Adapter 40: VW771/40  from the Slide Hammer Set: VW771 
  Fig 4: Identifying Slide Hammer Set

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• Hose Clamps - Up To 25 mm: 3094 
  Fig 5: Hose Clamps

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• Engine Bung Set: VAS6122 
  Fig 6: Engine Bung Set

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• M10 x 20 hex bolt
• Lubricating Grease for Clutch Plate Splines
• Refer to the Parts Information for the grease allocation.

-- If the Engine Support Bridge: 10-222A  does not yet have a hole with an -arrow- marked on it, do so now.

• Dimension -a- = 225 mm
• Hole diameter = 12.5 mm

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Disconnect the battery ground cable. Refer to BATTERY, DISCONNECTING AND CONNECTING .

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

-- Remove the battery and the battery tray -1- -arrows-. Refer to BATTERY, REMOVING AND INSTALLING .

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-- Remove the shift cable lock washer -1- from the transmission selector lever -2-. Remove the cable from the pin -arrow-.

-- Remove the cable retainer from the selector cable.

• To avoid damage to the selector cable, the cable retainer must be disconnected from the selector lever before removal.

-- Pull the safety mechanism all the way forward in -direction of arrow 1-. Then lock it to the left in -direction of arrow 2-.

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

-- Remove nut -1- and bolts -2- and set the cable bracket and cables off to the side.

-- Clamp off the hose line -A- to the clutch slave cylinder with Hose Clamps - Up To 25mm: 3094  .

-- Place a lint-free cloth under the bleeder.

-- Remove the clip -arrow- all the way and then remove the hose/line assembly -A- from the bleeder.

-- Tie up the line.

-- Seal the open lines and connections with clean plugs from the Engine Bung Set: VAS6122  .

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

-- Remove the windshield wiper arms. Refer to WINDSHIELD WIPER ARMS, REMOVING AND INSTALLING .

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

-- Disconnect any hoses and cables located near the engine lifting eyes for the Engine Support Bridge: 10-222A  .

-- Mount the Engine Support Bridge: 10-222A  as follows:

The following are needed:

• Engine Support - Adapter 1: 10-222A/31-1 
• Engine Support - Adapter 2: 10-222A/31-2 
• Engine Support - Basic Set - Square Pipe: T40091/1 
• Engine Support - Joint Fixture: T40091/3 
• Engine Support - Supplement Kit Spindle: T40093/3 
• Engine Support Brackets: T40093/3-6 
• Engine/Gearbox Support Shackle: 10-222A/12 

-- Remove the caps over the suspension strut threaded connections.

-- Place the Engine Support Bridge - Engine Support 31 Adapter 1: 10-222A /31-1  and Engine Support Bridge - Engine Support 31 Adapter 2: 10-222A /31-2  on the suspension strut mounts.

The tabs -arrow- face the engine compartment.

-- Slide the Engine Support - Supplement Kit Adapter 3: T40091/3  onto the Engine Support Bridge: 10-222A  .

-- Fasten the Engine Support Bridge: 10-222A  on the Engine Support Bridge - Engine Support 31 Adapter 1: 10-222A /31-1  and on the Engine Support Bridge - Engine Support 31 Adapter 2: 10-222A /31-2  .

-A- = Engine Support Brackets: T40093/3-6A  (see the next illustration).

-- Remove the fuel filter and set off to the side. Do not open the line system. Refer to OVERVIEW - FUEL FILTER .

-- If present, remove wires from the front area of the tab on the longitudinal member -arrow-. Do not disconnect the line system

-- Position the Engine Support Brackets: T40093/3-6  on the right longitudinal member.

-- If necessary, carefully unclip the A/C system pipe in the front area. Do not disconnect the line system. Refer to SYSTEM OVERVIEW - REFRIGERANT CIRCUIT .

• The Engine Support Brackets: T40093/3-6  locks with the pins -A- behind the tab on the longitudinal member -arrow-.

-- Install the Engine Support - Supplement Kit Spindle: T40093/3  .

-- Connect the Spindle: T40093/3  to the Engine Support Bridge: 10-222A  using the Square Pipe: T40091/1  and tension (see the previous illustration).

• The Engine Support - Basic Set Square Pipe: T40091/1  must be flush with the Engine Support - Basic Set Movable Joint: T40091/3  and the Engine Support - Supplement Kit Spindle: T40093 /3  (→ previous illustration).

-- Then engage the Spindles in the lifting eyes, as shown.

-- Lightly pretension the engine/transmission assembly and Engine Support Bridge using the Spindles.

-- Disconnect the front left connectors from the transmission:

1. Transmission for vehicles with start/stop system: Transmission Neutral Position Sensor -G701-
2. Back-Up Lamp Switch -F4-

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

-- Remove the lower section of the left front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

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

-- If the upper bolt for the starter cannot be removed, remove the breather. Refer to Fig 17.

-- Disconnect the connector -1- from the Oil Level Thermal Sensor -G266-.

-- Remove the subframe without the steering gear. Refer SUBFRAME WITHOUT STEERING GEAR, REMOVING AND INSTALLING to .

-- If equipped, remove the drive axle heat shield -arrows-. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

-- Remove the drive axles from the flange shafts and tie them up as high as possible. Be careful not to damage the surface protection. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Disconnect the exhaust system behind the particulate filter. Refer to OVERVIEW - MUFFLER .

-- If present, remove the nut -arrow- and ground cable.

-- Remove the bolts -arrows- from the transmission mount.

-- Turn the spindles on the Engine Support Bridge: 10-222A  and lower the transmission by dimension -a-.

• Dimension -a- = 60 mm

-- Remove the bolts -arrows- and then remove the transmission bracket from the transmission.

-- Remove the bolts -2- from the transmission/engine connection.

The transmission to engine connection bolts -1- and -3- will be removed later in the procedure.

The Transmission Support: 3282  is equipped with the Transmission Support - Mounting Plate 33: 3282/33  in order to remove the transmission.

-- Align the arms of the Transmission Support so that they align with the holes in the Adjustment Plate.

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

-- Install the Transmission Support - Pins 29: 3282/29  instead of the Mounting Element -C-.

-- Align the Adjusting Plate and transmission so that they are parallel to each other.

-- Install the Transmission Support - Pins 29: 3282/29  into the rear hole for the pendulum support bolt on the transmission.

-- Secure the Slide Hammer Set - Adapter 40: VW771/40  inside the threaded hole in the transmission housing as illustrated.

-- Secure the transmission on the Transmission Support: 3282  using an M10 X 20 bolt -A-.

The drift -B- must be flush at the bottom with the guide on the Transmission Support: 3282  -arrow-.

-- Position the Engine and Gearbox Jack: VAS6931  under the vehicle. The arrow on the adjusting plate points in the direction of travel.

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

-- Remove the last transmission to engine connecting bolt -arrow-.

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

-- Carefully lower the transmission while guiding the right flange shaft past the hole -arrow 1- on the intermediate plate and the flywheel -arrow 2-.