Transmission, Removing

Special tools and workshop equipment required

Engine Support Bridge 10 - 222 A
Bracket For Engine 10 - 222 A /1
Engine/Transmission Jack V.A.G 1383 A
Transmission Support 3282
Shackle 10 - 222 A /12
Hose Clamps Up to 25 mm Dia. 3094
Pry Lever - Rmv Outside Mirror 80 - 200
Pin 3282/29
Adjustment Plate 3282/42 A
Engine Bung Set VAS 6122
Hose Clip Pliers VAS 6340

Removing

NOTE:

Refer to REPAIR INFORMATION .

Refer to CLEAN WORKING CONDITIONS .

Refer to TRANSMISSION .

When installing, bring all cable ties back to same positions.

-- Turn off the ignition.

For this engine there are two different versions.

Version 1, with Side Air Filter Housing :

-- Disconnect the connector -1- on the mass air flow sensor -G70-.

Fig 1: Air Flow Housing, Electrical Connector And Guide Hose

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-- Remove the air guide hose -2-.

-- Remove the screw -4- and the air filter housing.

NOTE:

Ignore -3-.

-- Remove the engine cover -arrows-.

Fig 2: Removing Engine Cover

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Version 2, with Air Filter Inside the Engine Cover :

-- Disconnect the connector -3- on the mass air flow sensor.

Fig 3: Identifying Air Intake Hose Components

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-- Open the clips -1 and 2- and remove the air guide hose from the mass air flow sensor.

-- Open the spring clamps -4- remove the air intake hose from the engine cover.

CAUTION:

Danger of breaking the engine cover.

Always follow the removal sequence.

-- Carefully remove the engine cover from -1 - 2 - 3 - 4-.

Fig 4: Engine Cover Stop Removal Sequence

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All Vehicles:

-- Move the selector lever into P.

CAUTION:

Risk of destroying electronic components when disconnecting the battery.

Observe measures for disconnecting battery.

-- Remove battery. Refer to Removal and Installation .

-- Remove the bolts -arrows- and the battery carrier.

Fig 5: Battery Carrier Nuts

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-- Move the securing clamps -A- and remove.

Fig 6: Bolts For Support Bracket, Pulling Off Retaining Clip Upward & Disconnecting Selector Lever Cable From Transmission

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-- Press selector lever cable from the transmission shift lever -arrow- and place above.

-- Remove the bolts -1-.

NOTE:

Do not bend the selector lever cable.

Ignore -B, C, D-.

-- Remove the starter. Refer to Removal and Installation .

Fig 7: Ground (GND) Cable, Electrical Connector, Cable Tie & Protective Boot

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-- Disconnect the ground (GND) wire -3-.

Fig 8: Identifying Control Module Connectors

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CAUTION:

There is a risk of destroying the control module (Mechatronic) with static discharge.

Do not touch contacts in transmission connector with hands.

-- To discharge static, touch vehicle ground with hand (without glove).

-- Turn and disconnect the connector -4- on the transmission.

NOTE:

Ignore -1, 2- and -arrows-.

-- Mark coolant hoses to transmission fluid cooler to prevent mix-ups when installing.

-- Remove the coolant hoses of the transmission fluid cooler with 3094 and remove from transmission oil cooler -A-.

Fig 9: Gear Oil Cooler Hoses Clamped Off Using - 3094 - And Gear Oil Cooler

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-- Seal any open lines and connections with a clean plug from the VAS 6122.

-- Remove all the bolts in the transmission to engine connection that are accessible from above.

Fig 10: Direct Shift Automatic Transmission To Engine Mounting Bolts

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NOTE:

The bolt -3- is located in the opening for the starter.

-- If required, release the seal clip with the 80 - 200 and open up the seal.

Fig 11: Removing Seal Clip

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-- Disconnect any hoses and cables in the area of the 10 - 222 A lifting eyes on the engine.

Fig 12: Engine Support Bridge 10-222A

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-- Set 10 - 222 A on the bolted fender flanges (vehicles until 05.2008) or the steel plate (vehicles after 05.2008), as shown in the illustration.

-- Slightly pretension the engine with the spindle, do not lift.

-- Lift the vehicle.

Fig 13: Center Noise Insulation Bolts

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-- Remove the noise insulation. Refer to Removal and Installation .

NOTE:

Depending on the version, different noise insulation may be installed.

-- Remove the wheel housing liner in the front section to the left and right. Refer to Removal and Installation .

Fig 14: Identifying Removal Of Left And Right Front Part Of Wheel Housing Liner

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NOTE:

Depending on the version, different wheel housing liner may be installed.

-- Remove the front wheels.

-- If installed, remove guard plate at bottom of transmission -arrows-.

Fig 15: Protective Plate At Bottom Of Transmission

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-- Remove the bracket for the exhaust system -arrows-.

Fig 16: Bracket For Exhaust System

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-- Unclip the bracket -2- from the electrical wire to the oil level thermal sensor -G266- on the subframe.

Fig 17: Identifying Oil Level Thermal Sensor G266 Wire On Subframe

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-- Remove the wires and bracket on the front of the transmission.

Fig 18: Electrical Wiring

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NOTE:

Bracket is secured at front of transmission fluid pan.

-- Separate the exhaust system at the clamping sleeve -arrows-.

Fig 19: Disconnecting Exhaust System At Double Clamp

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-- Slide the clamping sleeve back.

-- Tie up the exhaust pipe.

NOTE:

Do not bend the exhaust system flex joint more than 10° or it could be damaged.

-- Mark the position of driveshaft with flexible disc to bevel box flange.

Fig 20: Driveshaft Flexible Disc

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-- Remove the driveshaft and flexible disc from the bevel box flange shaft -arrows-.

NOTE:

In order to loosen the bolts, hold a lever against the driveshaft flange/final drive.

-- Slide front driveshaft tube as far back as possible.

CAUTION:

Sealing ring -arrow- in driveshaft flange must not be damaged when removing transmission. If seal is damaged, driveshaft must be replaced.
When loosening pedal support/subframe bolts, engine/transmission assembly moves forward slightly.

Fig 21: Identifying Sealing Ring In Driveshaft Flange

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-- Remove the bolts -2- and -3-.

Fig 22: Identifying Pendulum Support & Bolts

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-- Push the assembly forward slightly remove the driveshaft from the bevel box.

-- Lift up driveshaft and secure with wire.

-- Tighten the subframe crossbrace before removing. Refer to Removal and Installation

-- Remove the pendulum support. Refer to Description and Operation

-- Remove the left transverse link bracket. Refer to Removal and Installation

-- Remove the catalytic converter support by removing the bolts -1- and -2- if applicable.

Fig 23: Front Exhaust Pipe With Catalytic Converter Support Bolts And Font Exhaust Nuts

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-- Remove the right drive axle heat shield from bevel box -arrows-.

Fig 24: Drive Axle Heat Shield

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-- Remove the left and right drive axle from the transmission flange shafts.

-- Lift up right drive axle and secure with wire.

-- Remove the left drive axle from the wire and move it back.

-- Remove the transmission carrier bolts on the bevel box -arrows 1- and engine -arrows 2-.

Fig 25: Identifying Oil Level Thermal Sensor Bolts

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NOTE:

Only remove transmission carrier if the transmission was removed from the engine.

-- If equipped, remove the small cover plate -A- behind bevel box -arrow-.

Fig 26: Small Cover Plate For Flywheel Behind Bevel Gear Transfer Case

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

Fig 27: Identifying Transmission Support Plate And Bolts

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-- Lower the transmission by adjusting the spindles on the 10 - 222 A by the degree of -a-.

Fig 28: Identifying Transmission Adjusted/Lowered To Dimension By Adjusting Spindles

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-a- = 60 mm

To remove the 3282, the transmission support is equipped with the 3282/42 A and positioned on the V.A.G 1383 A.

Fig 29: Direct-Shift Gearbox 02E

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-- Align the arms of the transmission support to correspond with the holes in the 3282/42 A.

-- Install the support elements on the 3282/42 A as shown. The retaining plate with the hole is used as a front support element.

-- Place the V.A.G 1383 A under the vehicle.

The arrow symbol on the adjustment plate points in the direction of travel.

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

-- Screw the 3282/29 into the transmission.

-- Attach the retaining plate with hole securely to the transmission -arrow- as shown.

-- Insert the last support element in the transmission as shown.

-- Support the transmission from underneath with the V.A.G 1383 A.

-- Remove the remaining bolts from transmission to engine connection.

-- Remove the transmission from the alignment sleeves.

-- Remove the transmission from engine at bevel box side and then at front side.

-- Carefully lower transmission over V.A.G 1383 A, making sure no wires are pinched.

-- Use spindles on the 3282 to adjust the position of the transmission while lowering it.

Special tools and workshop equipment required

Engine Support Bridge 10 - 222 A
Bracket For Engine 10 - 222 A /1
Engine/Transmission Jack V.A.G 1383 A
Transmission Support 3282
Shackle 10 - 222 A /12
Hose Clamps Up to 25 mm Dia. 3094
Pry Lever - Rmv Outside Mirror 80 - 200
Hooks 3004
Pin 3282/29
Adjustment Plate 3282/42 A

Removing

NOTE:

Refer to REPAIR INFORMATION .

Refer to CLEAN WORKING CONDITIONS .

Refer to TRANSMISSION .

When installing, bring all cable ties back to same positions.

-- Turn off the ignition.

CAUTION:

Risk of destroying electronic components when disconnecting the battery.

Observe measures for disconnecting battery.

-- Remove molded tool insert under luggage compartment floor covering.

-- Remove battery compartment cover -arrow-.

Fig 1: Battery Compartment Cover

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-- Remove molded insert over battery.

-- Disconnect the battery. Refer to Removal and Installation .

Fig 2: Battery Ground (GND) Cable

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-- Remove vacuum hose -2- on air duct hose.

Fig 3: Identifying Mass Air Flow (MAF) Sensor G70 Electrical Harness Connector

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-- Remove air guide hose -1- on the throttle valve control module -J338-.

-- Disconnect the connector -3- on the mass air flow sensor -G70-.

-- Remove upper section of air filter -arrow-.

-- Remove filter insert.

-- Remove air duct cover -1-.

Fig 4: Air Duct Cover & Air Duct

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-- Unclip air duct -2-.

-- Remove the lower section of the air filter -arrows-.

Fig 5: Identifying Screws For Lower Portion Of Air Cleaner Housing

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-- Remove air filter housing -arrows-.

Fig 6: Air Filter Housing Bracket

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-- Move the selector lever into P.

Fig 7: Bolts For Support Bracket, Pulling Off Retaining Clip Upward & Disconnecting Selector Lever Cable From Transmission

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-- Move the securing clamps -A- and remove.

-- Press selector lever cable from the transmission shift lever -arrow- and place above.

-- Remove the bolts -1-.

NOTE:

Do not bend the selector lever cable.

Ignore -B, C, D-.

-- Disconnect the connectors -1- and -3-.

Fig 8: Electrical Connectors, Starter Solenoid Switch And Ground Cable

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-- Remove electrical wire -2- at starter solenoid switch.

-- Remove the ground (GND) wire -4-.

CAUTION:

There is a risk of destroying the control module (Mechatronic) with static discharge.

Do not touch contacts in transmission connector with hands.

-- To discharge static, touch vehicle ground with hand (without glove).

-- Twist bayonet connection -5- of 20-pin connector to release it from transmission, and disconnect.

-- Remove the starter. Refer to Removal and Installation .

-- Mark coolant hoses to transmission fluid cooler to prevent mix-ups when installing.

-- Remove the coolant hoses of the transmission fluid cooler with 3094 and remove from transmission oil cooler -A-.

Fig 9: Gear Oil Cooler Hoses Clamped Off Using - 3094 - And Gear Oil Cooler

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-- Seal any open lines and connections with a clean plug from the engine bung set VAS 6122.

-- Remove all engine/transmission bolts that can be reached from the top.

Fig 10: Identifying Bolts On Engine/Transmission Flange

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-- If required, release the seal clip with the 80 - 200 and open up the seal.

Fig 11: Removing Seal Clip

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-- Disconnect any hoses and cables in the area of the 10-222 A lifting eyes on the engine.

Fig 12: Securing Shackle 10-222 A/12 At Right Rear Engine Lifting Eye

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-- Set 10 - 222 A on the bolted fender flanges (vehicles until 05.2008) or the steel plate (vehicles after 05.2008), as shown in the illustration.

-- Engage spindles in lifting eyes or at shackles.

-- Preload the engine/transmission subassembly slightly using the spindle.

-- Remove the noise insulation. Refer to Removal and Installation .

Fig 13: Center Noise Insulation Bolts

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NOTE:

Depending on the version, different noise insulation may be installed.

-- Remove the wheel housing liner in the front section to the left and right. Refer to Removal and Installation .

Fig 14: Identifying Removal Of Left And Right Front Part Of Wheel Housing Liner

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NOTE:

Depending on the version, different wheel housing liner may be installed.

-- Remove the front wheels.

-- If installed, remove guard plate at bottom of transmission -arrows-.

Fig 15: Protective Plate At Bottom Of Transmission

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-- Remove the bracket for the exhaust system -arrows-.

Fig 16: Bracket For Exhaust System

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-- Unclip the bracket -2- from the electrical wire to the oil level thermal sensor -G266- on the subframe.

Fig 17: Identifying Oil Level Thermal Sensor G266 Wire On Subframe

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-- Remove bolts -1- and -4- and remove bracket.

Fig 18: Identifying Secondary Air Injection (AIR) Pump Motor V101 Electrical Harness Connector

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-- Remove nut -1- and press bracket -A- upward so that it does not hang when transmission is lowered.

Fig 19: Locating Bracket And Nut

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NOTE:

Bracket -A- is secured at front of transmission fluid pan.

-- Disconnect exhaust system at double clamp -arrows-.

Fig 20: Disconnecting Exhaust System At Double Clamp

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-- Slide the clamping sleeve back.

-- Tie up the exhaust system with a chain. To do this, insert 3004 into openings at vehicle floor (remove plug, if necessary).

Fig 21: Identifying Chain To Tie Exhaust System In Position With Hooks -3004-

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NOTE:

Do not bend the exhaust system flex joint more than 10° or it could be damaged.

-- Remove the right drive axle heat shield from bevel box.

Fig 22: Identifying Right Driveshaft Heat Shield And Bevel Box

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-- Remove the left and right drive axles from the transmission flange.

-- Lift up right drive axle and secure with wire.

-- Remove the left drive axle from the wire and move it back.

-- Identify position of flexible disc and bevel box flange to each other.

Fig 23: Identifying Bevel Gear Transfer Case Flange Bolts

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-- Remove the driveshaft flexible disc at bevel box -arrows-.

NOTE:

In order to loosen the bolts, hold a lever against the driveshaft flange/final drive.

-- Slide front driveshaft tube as far back as possible.

CAUTION:

Sealing ring -arrow- in driveshaft flange must not be damaged when removing transmission. If seal is damaged, driveshaft must be replaced.
When loosening pedal support/subframe bolts, engine/transmission assembly moves forward slightly.

Fig 24: Identifying Sealing Ring In Driveshaft Flange

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-- Remove the bolts -2- and -3-.

Fig 25: Identifying Pendulum Support & Bolts

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-- Push the assembly forward slightly and remove the driveshaft from the bevel box.

-- Remove the driveshaft above the bevel box and secure this from falling down.

-- If equipped, remove left front level control system sensor -G78- -arrows-.

Fig 26: Installing Front Level Control System Sensor

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-- Remove the subframe. Refer to Removal and Installation .

Fig 27: Locating Pins T10096 Installation Position

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CAUTION:

To remove control arm console, you must use the locating pins T10096. Refer to Removal and Installation .

-- Remove the left transverse link bracket form the body. Refer to Removal and Installation .

-- Remove nuts -1 - and bolts -2- at bevel gear transfer case bracket.

Fig 28: Bevel Box Bracket & Bolts

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-- Remove bracket -A- for bevel gear transfer case.

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

Fig 29: Identifying Transmission Support Plate And Bolts

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-- Lower the engine/transmission assembly using the spindle.

Fig 30: Securing Shackle 10-222 A/12 At Right Rear Engine Lifting Eye

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Dimension -a- between the transmission housing and transmission bearing must = 100 to 110 mm.

Fig 31: Dimension Between Transmission Housing And Transmission Bearing
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To remove the 3282, the transmission support is equipped with the 3282/42 A and positioned on the V.A.G 1383 A.

Fig 32: Direct-Shift Gearbox 02E

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-- Align the arms of the transmission support to correspond with the holes in the 3282/42 A.

-- Install the support elements on the 3282/42 A as shown. The retaining plate with hole is used as a front support element.

-- Place the V.A.G 1383 A under the vehicle.

The arrow symbol on the adjustment plate points in the direction of travel.

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

-- Screw the 3282/29 into the transmission.

-- Attach the retaining plate with hole securely to the transmission -arrow- as shown.

-- Insert the last support element in the transmission as shown.

-- Support the transmission from underneath with the V.A.G 1383 A.

-- Remove the remaining bolts from transmission to engine connection.

-- Remove the transmission from the alignment sleeves.

-- Remove the transmission from engine at bevel box side and then at front side.

-- Carefully lower transmission over V.A.G 1383 A, making sure no wires are pinched.

-- Use spindles on the 3282 to adjust the position of the transmission while lowering it.