Transmission, Removing
Transmission, Removing
Special tools, testers and auxiliary items required
• Engine Support Bridge (10 - 222 A)
• Hook (10 - 222 A /10)
• Hose Clamps Up to 25 mm Diameter. (3094)
• Transmission Support (3282)
• Pin (3282/29)
• Adjustment Plate (3282/33)
• Engine/Transmission Jack (V.A.G 1383 A)
• Engine Support Basic Set (T40091)
• Engine Support Supplement Set (T40093)
• Adapter (VW 771/40)
• Bracket (T10338)
• M10x20 bolt
• Grease (G 000 450 02)
• Grease for clutch disc shaft splines (G 000 100)
Procedure
• Observe general repair notes. Refer to => [ General Repair Information ] General Repair Information.
• Reinstall cable ties that were loosened or cut off during removal at same locations during installation.
Risk of destroying electronic components when disconnecting the battery.
• Observe measures for disconnecting battery.
- With the ignition switched off, disconnect the battery ground (GND) cable.
- Remove the entire air filter housing.
- Remove line - 1 - from air filter bracket - 2 -.
- Remove bolts - arrows - and remove air filter bracket.
- Remove the shift cable lock washer - 3 - from the transmission shift lever - 1 - and remove the cable from the pins - arrow -.
- Remove lock washer - 1 - and remove the control cable retainer from the pin.
Metal selector relay lever
- Remove lock washer - 2 - and remove the control cable retainer from the selector relay lever.
Plastic selector relay lever
• To avoid damage to the selector cable, the control cable retainer must be disconnected from the selector cable before removal.
- Pull the securing mechanism forward as far as the stop in the direction of - arrow 1 - and then unlock to the left in the direction of - arrow 2 -.
- Then press the selector relay lever forward (direction of - arrow 3 -).
• The control cable retainer may only be removed with the selector relay lever removed => [ Pry the Selector Cable Retainer
Out of the Selector Relay Lever ] Shift Cable and Selector Cable From Model Year 2008 Assembly Overview
All Vehicles
- Remove cable mounting bracket from transmission - arrows - and tie it up off to the side with the cables.
- When a plastic line is installed between the clutch master and slave cylinder, clamp off the return line to the clutch master cylinder with (3094).
• During the following procedures, make sure that brake fluid does not leak onto the starter or the transmission. If this happens, these areas must be cleaned thoroughly.
• To prevent dirt from entering, seal open lines and connections with clean plugs or protective caps.
- If a hose/line assembly is installed between the clutch master and slave cylinder, clamp off hose - A - with (3094).
• Pay no attention to - arrow -.
- Pull out the clip - arrow - to the stop.
- Remove the plastic line or hose/line assembly - A - from the bleeder/clutch slave cylinder and seal it off.
• Disregard item - B -.
Clutch pedal must no longer be operated.
- Disconnect electrical harness connector - 1 - for back-up light switch (F4).
- Remove the ground (GND) cable - 2 -.
- Then remove upper starter mounting bolt under ground (GND) cable - 2 -.
- Disconnect electrical connector - 3 -.
- Slide cover - 4 - back.
- Disconnect the electrical wire - arrow - from the starter.
- Remove upper engine/transmission bolts - arrows -.
- Install (T10338) on open threaded hole at left rear of engine.
- Position (10 - 222 A) on bolted fender flange with the following tool components:
• Bracket for engine (10 - 222 A /1), qty. 2
• Bracket with spindle and hook (10 - 222 A /10) (spindle faces toward rear)
• Spindle (10 - 222 A /11) (spindle faces toward front)
• Shackle (10 - 222 A /12)
• Connectors (T40091/3), qty. 2
- Engage (10 - 222 A /11) with (10 - 222 A /12) on right engine lifting eye.
- Engage (10 - 222 A /10) on (T10338).
- Lightly tension the engine/transmission assembly with the spindles.
- Connect (T40093/3) (qty. 2) with left side (T40093/3-2) or right side (T40093/3-3).
- Disconnect ground (GND) cable from left long member.
- Remove left and right connecting bolts for front part of long member.
- Install (T40093/3-2) (left) and (T40093/3-3) (right) on the long members with the previously removed bolts - arrow -.
• The left side of the vehicle is shown in the illustration.
- Insert (T40091/1) in (T40091/3) and (T40093/3) as shown in illustration.
- Slide (T40093/4) onto square tube.
- Slide (T40091/2) with (T40093/5) into both (T40093/4).
Risk of an accident due to loose support bridge parts.
• Secure (T40091/2) with pins and splints from (T40093/4).
• Secure connector and supports with locking bolts.
- Install (10 - 222 A /11) on slide and engine lifting eye.
- Tension the engine/transmission assembly by tightening the 3 spindles evenly.
- Remove both front wheels.
- Remove noise insulation in center by loosening fasteners - 1 through 4 -.
- Remove left and right noise insulation - arrows -.
- Remove the noise insulation frame - arrow -.
- Remove nut - 3 - and remove wiring harness bracket - 2 -.
- Remove starter mounting bolt - 1 - and starter.
- Disconnect electrical connector - 1 - on oil level thermal sensor (G266).
- Unclip bracket - 2 - for electrical wire to oil level thermal sensor on subframe.
- Remove exhaust system bracket bolts - arrows -.
- Remove the bolts - 2 - and - 3 -.
- To avoid axle alignment, secure the subframe.
- Remove subframe.
- Remove right drive axle heat shield from bevel box - arrows -.
- Remove the left drive axle from transmission flange shaft.
- Remove the right drive axle from the bevel box flange shaft.
- Raise drive axles and secure with cable ties.
• Make sure drive axle protective coating is not damaged.
- Remove the bolts - arrows - and remove the bevel box bracket.
- Identify position of flexible disc and bevel box flange to each other.
- Remove driveshaft flexible disc from bevel box - arrows - while counterholding at triangular flange with a lever.
- Press engine/transmission assembly slightly forward (toward front end) and pull off driveshaft from bevel box.
Risk of damaging sealing ring - arrow - in driveshaft flange.
• Press driveshaft horizontally as far back and to the right side of the vehicle as possible.
• If seal is damaged, driveshaft must be replaced.
- Tie driveshaft up.
- Remove screw above bevel box - arrow -.
- Remove the bolts - arrows - from the assembly mounting on the transmission.
- Lower the transmission by adjusting the spindles of the (10 - 222 A) by dimension - a -.
• Dimension - a - = 70 mm.
- Remove transmission bracket from transmission - arrows -.
Metal selector relay lever - 1 -:
- Remove lock washer - arrow - and remove selector relay lever - 1 -.
Plastic selector relay lever - 1 -
- Remove the selector relay lever with catch => [ Remove the Selector Relay Lever
with Catch from the Transmission Shift Lever and
Attach ] Shift Cable and Selector Cable From Model Year 2008 Assembly Overview
- Remove the selector relay lever with catch => [ Remove the Selector Relay Lever from the Transmission Shift Lever and
Attach ] Shift Cable and Selector Cable From Model Year 2008 Assembly Overview
All Vehicles
- Remove engine/transmission connecting bolt - arrow - (engine side).
- Remove engine/transmission connecting bolt - arrow - near bevel box - C -.
Make sure securing clip - A - for bolt - arrow - in engine oil pan - B - is installed.
Transmission support (3282) is equipped with (3282/33) to remove transmission "02Q".
- Place (3282) in (V.A.G 1383 A).
- Align arms of transmission support according to holes in adjustment plate.
- Install support elements - A - onto adjustment plate as shown.
- Install (3282/29) in place of attachment - C -
- Place (V.A.G 1383 A) under the vehicle with the arrow symbol - B - on the adjustment plate pointing in the direction of travel.
- Align adjustment plate and transmission parallel to one another.
- Screw (3282/29) into hole for mounting bolt of pendulum support on transmission.
- Secure (VW 771/40) in threaded hole of transmission housing as depicted in the illustration.
- Secure the transmission on the (3282) using bolt M10x20 - A -.
- Remove last lower engine/transmission connecting bolts - 1 to 3 -.
- Press transmission off of engine and turn upward in differential area. Guide the transmission past driveshaft - A - and front exhaust pipe - B - with output flange - C -. Rotate the output flange if necessary.
• Also note area between bevel box and intermediate plate/engine.
- Press off transmission from alignment sleeves.
- Carefully lower transmission.
• Pay attention to electromechanical steering gear when lowering the transmission.