Transmission, Removing, Vehicles With Gasoline Engine And Fwd

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

Special tools and workshop equipment required

Engine Support Bridge: 10-222A
Engine Support Bridge - Engine Support 29: 10-222A/29
Engine Support Bridge - Engine Support 18: 10-222A/18
If necessary Engine/Gearbox Support Shackle: 10-222A/12
Transmission Support - Pins 29: 3282/29
Transmission Support: 3282
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
Slide Hammer Set - Adapter 40: VW771/40
Engine Support Brackets: T40093/3-6A (quantity: 2)
Engine Support Bridge - Special Hook: 10-222A/20
Square Pipe: T40091/1 (quantity: 2)
Engine Support - Joint Fixture: T40091/3 (quantity: 2)
Spindle: T40093/3 (quantity: 2) from the Engine Support Supplement Set: T40093B
Engine Sling - Engine Bracket: 2024A/1 from Engine Sling: 2024A
Hose Clamps - Up To 25 mm: 3094
Engine Bung Set: VAS6122
Lubricating Grease for Clutch Plate Splines
Determine the shift mechanism grease using the Parts Information.
M10 x 20 hex bolt

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

-- If equipped, unlock the retainer in direction of -arrow- and remove the left engine cover mount -1-.

Fig 1: Identifying Engine Cover Mount

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-- If equipped, unclip the right engine cover mount -1- from the bracket -2-.

Fig 2: Identifying Engine Cover Mount And Locating Bore

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

-- Remove the 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-.

Fig 3: Identifying Lock Washer -1- And Pin -Arrow- On Transmission Shift Lever -2-

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-- Remove the cable retainer from the selector cable.

Fig 4: Disconnecting Cable Retainer From Selector Cable

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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-).

NOTE:

Only remove the cable retainer when the relay lever is removed. Refer to Figure.

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

Fig 5: Locating Bracket Nuts And Bolts

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-- Clamp off the hose line -A- to the clutch slave cylinder with : 3094 .

Fig 6: Clamping Off Hose/Line Assembly Hose To Slave Cylinder With Hose Clamps

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

NOTE:

Brake fluid must not come into contact with the longitudinal member or transmission. If it does, clean the area thoroughly.

-- 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 : VAS6122 .

CAUTION:

There is a risk of contamination from the leaking brake fluid.

Do not use the clutch pedal if the hose/line assembly from the clutch slave cylinder bleeder is disconnected.

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

Fig 7: Identifying Bolts At Engine/Transmission Flange

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

-- Mount the : 10-222A as follows:

The following are needed:

: 10-222A/18
: 10-222A/12 (required if the Spindle on the Engine Support Bridge cannot be engaged in the engine lifting eye)
: 10-222A/29 (quantity: 2)
: T40091/1 (quantity: 2)
: T40091/3 (quantity: 2)
: T40093 /3 (quantity: 2)
: T40093/3-6A (quantity: 2)
: 10-222A/20

-- On both sides of the vehicle, insert the : 10-222A/29 between the fender bolting edge and the fender bolting plate underneath it.

Fig 8: Identifying Engine Support

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Installation position:

"L" = -1- Adapter is inserted on the "right" side of the vehicle (Adapter locks in place in the fender opening).

"R" (not illustrated here), Adapter is installed on the "left" side of the vehicle.

The arrow -2- always points in driving direction

-- Slide the : 10-222A/18 and the two : T40091/3 onto the : 10-222A .

Fig 9: Identifying Engine Support Bridge

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-- Tighten the : 10-222A on the : 10-222A/29 .

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

-- Remove the filler tube for the windshield washer system washer fluid reservoir. Refer to WASHER FLUID RESERVOIR, REMOVING AND INSTALLING .

-- If present, remove wires from the front area of both longitudinal members -arrow-. Do not disconnect the line system

Fig 10: Identifying Engine Support Brackets

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-- Place the : T40093/3-6A on both longitudinal members (the right longitudinal member is illustrated here).

-- 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 : T40093/3-6A lock to the respective pin -A- behind the tab on the longitudinal member -arrow-.

-- Install the : T40093/3 .

-- Connect the : T40093/3 to the : 10-222A using the : T40091/1 and tension (see the previous illustration).

-- Engage the : 10-222A/12 in the engine lifting eyes and then the Spindles.

Fig 11: Identifying Engine Support 32 - Shackle

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

-- Disconnect the front left connectors from the transmission:

Fig 12: Identifying Park/Neutral Position Switch

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Transmission for vehicles with start/stop system: Transmission Neutral Position Sensor -G701-
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 the figure below.

Fig 13: Bleeder At Slave Cylinder, Removal/Installation

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

Fig 14: Disconnecting Connector From Oil Level Thermal Sensor G266

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For Front Axle Differential Lock

Fig 15: Locating Axle Differential Lock Control Module Connector

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-- Remove the connector -arrow- from the Differential Locks Control Module -J647-.

-- Remove the left charge air hose -1-. Refer to OVERVIEW - CHARGE AIR SYSTEM .

Fig 16: Identifying Hose And Clamps

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-- Remove the fan shroud with the radiator fan -arrow-. Refer to FAN SHROUD, REMOVING AND INSTALLING .

Fig 17: Fan Shroud

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-- If equipped, remove the Left Front Level Control System Sensor -G78- from the lower control arm. Refer to LEFT FRONT LEVEL CONTROL SYSTEM SENSOR -G78- /RIGHT FRONT LEVEL CONTROL SENSOR -G289-, REMOVING AND INSTALLING .

Fig 18: Identifying Left Front Level Control System Sensor

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

Fig 19: Drive Axle Heat Shield

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

-- Remove the left drive axle from the flange shaft. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Pivot the left suspension strut outward and support it with the : 2024A/1 as shown.

Fig 20: Securing Pin And Control Arm Secured Using Securing Pin And Nut

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WARNING:

Risk of accident due to loose support parts.

Secure the pin and ball joint with the securing pin -arrow- and nut -1-.

-- Tie the left drive axle up as much as possible while not damaging the protective coating. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

CAUTION:

Risk of damaging the decoupling element.

Pay attention. Refer to OVERVIEW - EMISSIONS CONTROL SYSTEM .

-- Remove the exhaust system from the engine and tie up. Refer to OVERVIEW - MUFFLER .

-- Remove the pendulum support.

Fig 21: Identifying Pendulum Support

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

Fig 22: Identifying Nut

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

Fig 23: Identifying Transmission Mount To Transmission Mount Bracket Bolts

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

Fig 24: Identifying Transmission Adjusted/Lowered To Dimension By Adjusting Spindles

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Dimension -a- = approximately 60 mm

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

Fig 25: Identifying Console From Transmission, Removal/Installation

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

Fig 26: Identifying Lower Connecting Bolts For Engine/Transmission

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

The : 3282 is equipped with the : 3282/33 to install the transmission.

Fig 27: Identifying Adjustment Plate Installed Onto Transmission Support

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-- 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 : 3282/29 instead of the Mounting Element -C-.

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

Fig 28: Identifying Engine/Transmission Connecting Bolt

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

-- Secure the : VW771/40 in the threaded hole of the transmission housing as illustrated.

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

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

-- Position the : 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 remaining engine/transmission bolts.

For Front Axle Differential Lock

Fig 29: Locating Engine/Transmission Connecting Bolt

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One of the engine/transmission connecting bolts -arrow- is located directly next to the front axle differential lock.

Continuation for All

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

-- Push the engine slightly forward (a second technician is needed).

-- Guide the right flange shaft -1- over the bolting eyelet of the engine -2-.

Fig 30: Guiding Right Flange Shaft Over Cylinder Block Bolt Flange

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Then guide the right flange shaft -1- past the flywheel and the opening -arrow- on the intermediate plate.

Fig 31: Guiding Right Flange Shaft Past Flywheel And Opening In Intermediate Plate

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-- Move the transmission near the differential into an angled position using the spindles from the : 3282 .

The differential must face upward.

-- Guide the transmission and the differential over the subframe and swing them out.

Fig 32: Identifying Longitudinal Member -Arrow 1- And Subframe -Arrow 2-

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-- Be careful of the longitudinal member -arrow 1- and of the subframe -arrow 2-.

-- If necessary, tilt the transmission slightly higher near the differential.

-- Carefully lower the transmission.

Fig 33: Identifying Tool Assembly To Lower Transmission

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For Front Axle Differential Lock

Fig 34: Locating Haldex Clutch Pump Connector

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Protect the All Wheel Drive Clutch Pump -V181- connector -arrow- against damage.

Continuation for all vehicles

NOTE:

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