Removing Sensor Module

Information 

1. VAS 6622A - Used oil collection and extraction unit  must be placed under the transmission.
2. Remove connector housing for sensor module

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   Connector housing for sensor module

   1. 2.1  Turn connector housing for sensor module -1-  fully to the left using > T40228 - bit  and pull it off.

   Information  : The output shaft and side shaft must not be damaged when removing or fitting the transmission housing cover.

3. Remove transmission housing cover -1-  .

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   Transmission housing cover

   1. 3.1  Remove screws -2 and 3-  .
   2. 3.1.1  Replace screws.
   3. 3.2  Pull off transmission housing cover -1-  .
4. Remove sealing ring on transmission housing cover -1-  and replace it.

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   Sealing ring on transmission housing cover

   Information 

   • Sealing faces must be free of oil and grease. 
5. Clean sealing faces on transmission housing cover.
6. Remove oil guide for drive shaft -1-  .

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   Oil guide for drive shaft

   Information 

7. Remove side shaft

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   Side shaft

   1. 7.1  Unscrew side shaft screw -2-  .
      1. 7.1.1  Push on bi-hexagonal socket insert (a/f 21) -3-  with extension -4-  and fit it on side shaft screw -2-  .
      2. 7.1.2  Insert ring gear of > T40217 - counterhold tool-6-  into ring gear of side shaft -7-  .
      3. 7.1.3  > T40217 - Counterhold tool-5-  must be secured to the centre transmission housing.
      4. 7.1.4  Unscrew and replace screw on side shaft -2-  .
   2. 7.2  > T40217 - Counterhold tool-5-  must now be removed.
   3. 7.3  Pull out the side shaft
8. Pull spur gear -1-  and needle-roller bearing -2-  off the output shaft -3-  .

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   Spur gear and needle-roller bearing

9. Position double clutch transmission on > VAS 6095A - engine and gearbox bracket  vertically so that the clutch side is facing downwards.

   Information 

   • The hooks and staking pins of the lifting tackle must be secured with cotter pins. 
   • The centre transmission housing must be lifted off carefully and in a vertical position in order to prevent the centre transmission housing from tilting. 
10. Suspend centre transmission housing -1-  on > VAS 6100 - workshop crane -2-  .

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    Transmission housing, centre

    1. 10.1  > T10014 - Retainer-3-  must be secured to the centre transmission housing
    2. 10.2  Secure VW771/40 -4-  from tool set > VW771 - Multi-purpose tool  on the centre transmission housing -1-  .
    3. 10.3  > 3368 - Eye-head bolt-5-  must be secured to VW771/40 -4-  .
    4. 10.4  > T10014 - Retainer-3-  and > 3368 - eye-head bolt-5-  must now be engaged in the > 2024A - lifting tackle-6-  .
    5. 10.5  > 2024A - Lifting tackle-6-  must be attached to the > VAS 6100 - workshop crane-2-  .
11. Remove centre transmission housing -1-  .
    Fig 1: Centre Transmission Housing Screws Loosening Sequence

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    Screws on centre transmission housing

    1. 11.1  Remove screws -2 to 18-  .
       1. 11.1.1  Replace screws.
    2. 11.2  Lift off centre transmission housing -1-  using > VAS 6100 - workshop crane  and set it down on the workbench with a suitable base.
    3. 11.3  > 2024A - Lifting tackle  must now be removed from the centre transmission housing -1-  .
12. Remove sensor module -1-  with oil collection pan -2-  .

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    Sensor module

    1. 12.1  Remove screw -3-  .
    2. 12.2  Remove sensor module -1-  and oil collection pan -2-  .
13. Remove sealing ring for front output shaft.
    • WM, 387055 - REPLACING SEALING RING FOR FRONT OUTPUT SHAFT 

    Information 

    • Sealing faces must be free of oil and grease. 
14. Clean sealing faces on transmission housing flange and centre transmission housing.