Transmission, Removing and Installing
Transmission, Removing and Installing
Removing
Prepare the following special tools and test equipment for use:
- 10-222 A engine support bridge
- 10-222 A/1 bracket for engine
- 10-222 A/3 engine support adapter
- VAG 1383A lift
- 3282 transmission support
- 3282/19 adjustment plate
- 3282/48 adapter
- 3282/52 adapter (3 pcs.)
- VAG 1306 drip tray
- 80-200 pry lever
- 3035 injector line wrench
- 3393 Testing Mandrels
- V175 special tool (nut)
- Note radio code (for vehicles equipped with coded anti-theft radio).
- Disconnect Ground (GND) strap from battery.
For 6 cylinder gasoline engines except for 2.7 Liter 5V turbo engine:
- Remove engine cover (arrows).
All except 2.7 Liter 5V turbo engine:
- Remove cover above air filter housing.
- Remove air guide -1- between air filter housing and lock carrier.
- Disconnect connector for Evaporative Emission (EVAP) canister purge regulator valve -2-, and remove valve from bracket. Disconnect connector -3- at Mass Air Flow (MAP) sensor.
- Remove intake air duct -4- from intake manifold.
- Remove upper part of air filter housing -5-.
- Unbolt engine coolant expansion tank and lay aside.
- Remove Heated Oxygen Sensor (HO2S) from front exhaust pipes (left and right).
- Remove upper securing nuts from front exhaust pipes (left and right).
For all 6 cylinder engines:
- Assemble both 10-222A/3 engine support adapters for front and rear spindles on support bar.
- Set 10-222A engine support bridge onto the fender mounting flanges using 10-222A/1 brackets
- Hang both spindles on the adapters.
- Secure engine to spindles. To do so, additionally use a shackle -1- at the rear side of the engine to avoid damage.
For 4 cylinder engines:
- Disconnect connector -A- from bracket -B-.
- Mount 10-222A/3 adapter for spindle at front of support.
- Install 10-222A engine support bridge with 10222A/1 brackets and support engine/transmission in this position.
All:
- Take up weight of engine/transmission assembly on spindles.
- Tighten the rear spindle less, to enable later lowering at rear.
- Raise vehicle.
- Remove front wheels.
- Remove sound-deadening pan.
- Remove left and right heat shields for drive axles (arrows).
- Disconnect drive axles from transmission drive flanges, refer to Drive Axles, Bearings and Joints - Axle Shaft Assembly - Service and Repair - Procedures Service and Repair
- Disconnect engine speed (RPM) sensor -G28- (arrow B) from transmission at front left (if installed).
- Remove connector for speedometer (arrow -A-) from transmission.
- Remove noise insulation bracket -1-.
- Swing securing lever -4-, disconnect connector for transmission wiring harness.
- Disconnect connector -2- of wire for multi-function switch.
- Unbolt bracket -3- for harness connector.
For 6 cylinder engines except for 2.7 Liter 5V turbo engine:
- Unclip vent hose for alternator -1-.
- Unbolt bracket for ATF line -2- at oil pan.
- Separate ATF lines -1- to ATF cooler.
- Plug ATF lines with clean plug.
- Unbolt bracket for ATF line -3-.
- Remove transmission side starter bolt -2-.
Vehicles with 4 cylinder engine
- Remove bolt -12- to separate bracket for ATF line -11- from engine.
- Remove bolt -1-.
- Pull off lines -2and -3- from transmission.
- Plug lines and openings at transmission with clean plugs.
- Lay lines aside so they are not damaged.
All except 2.7 Liter 5V turbo engine:
- Remove starter, refer to Starting and Charging - Starting System - Starter Motor - Service and Repair - Procedures
Disconnect torque converter from drive plate
For vehicles with hex bolts:
- Remove torque converter from drive plate by removing 3 bolts using special tool V175 (turn crank shaft an additional 1/3 turn every time).
For vehicles with Torx bolts:
- Unbolt 3 torque converter bolts from drive plate using respective Torx insert (turn crank shaft an additional 1/3 turn every time).
All-wheel-drive vehicles
- Remove heat shield -A- above driveshaft.
- Remove rear part of exhaust system if necessary:
- Remove heat shield -2- for driveshaft from cover for Torsen differential (arrows).
- Unbolt driveshaft from transmission and hang or support.
Continuation for all vehicles
- Position 3282 transmission support.
Use 3282/19 adjustment plate to position the 3282 transmission support for Automatic Transmission 01V.
The symbols on the adjustment plate indicate the necessary mounts and the arrow points toward front of vehicle.
- Roll VAG1 383A engine/transmission hoist with 3282 transmission support under transmission and support transmission.
- Align adjustment plate parallel to transmission.
- Secure transmission on 3282 transmission support using bolt -A-.
Automatic Transmission 01V with All Wheel Drive is supported at the same positions as the Front Wheel Drive version.
- Remove left and right transmission support with transmission mount, refer to Transmission Mount, A/T - Service and Repair - Procedures Service and Repair
- Unbolt multi-function Transmission Range (TR) switch -F125- for protection against damage (arrows) and expose wiring harness.
- Mark position of mounting bracket for selector lever cable to transmission housing for reinstallation, unbolt mounting bracket (arrows).
- If installed, press off securing brace (arrow) at end of selector lever cable.
- Pry off selector lever cable from lever/shift rod (arrow).
- Remove upper connecting bolts for engine/transmission.
For 6 cylinder TDI engines
- Loosen bolt -A- (at rear of turbocharger) several turns and rotate brace -B- to side in arrow direction. Then re-tighten bolt-A- lightly.
Note: Illustration depicts engine from rear with the transmission removed.
Continuation for all vehicles
- Before loosening subframe, it must be checked whether holes -1- and -2- (at least) line up using 3393 testing mandrel.
If this is not the case, an axle alignment must be performed after the carrier is installed.
- Remove bolts -1- and -2- at rear of subframe on both sides of vehicle.
- Completely remove bolts -3- at front of subframe on both sides of vehicle.
By removing the bolts, the subframe lowers itself approximately 150 mm at rear edge, Refer to illustration
- Slightly lower engine/transmission subframe at rear above VAG1383A hoist.
- Remove front exhaust pipes:
- Remove remaining connection bolts for engine/transmission.
- Press transmission off engine, while pressing torque converter out of drive plate.
- Press torque converter against the ATF pump (arrow).
- Rotate transmission (arrow) and carefully move into position between subframe and vehicle floor.
- Lower transmission.
- Secure converter so it does not fall out.
Installing
Installation is reverse of removal, noting the following:
Before installing:
All-wheel-drive vehicles
- Clean threads in driveshaft flange
Continuation for all vehicles
- Clean ATF lines
- Insert torque converter into transmission, refer to Torque Converter - Service and Repair - Procedures Service and Repair
WARNING: Check installation dimension of torque converter before installing transmission Service and Repair
- Make sure bushings are correctly seated.
Note: If the bushings get stuck in the transmission housing, they must be removed and new bushings must be installed on the engine.
For 4 cylinder engines (5 valve, turbo)
Item A, Refer to bushings
For 6 cylinder gasoline engines:
Item A, Refer to bushings
For 6 cylinder TDI engines
Item A, Refer to bushings
- Position 3282 transmission support.
Use 3282/19 adjustment plate to position the 3282 transmission support for Automatic Transmission 01V.
The symbols on the adjustment plate indicate the necessary mounts and the arrow points toward front of vehicle.
- Place transmission onto transmission support.
- Secure transmission on 3282 transmission support using bolt -A-.
- Move transmission into position between the lowered subframe and vehicle floor.
- Press the lever/shift rod -2- at transmission completely toward rear (toward right in illustration) until park lock is engaged.
- Shift selector lever into "P" and carefully press up ball head of selector lever cable on lever/shift rod -2- using a pair of pliers.
- If installed, press securing brace (arrow) open at end of selector lever cable.
Note: Do not deform lever/shift rod when pressing up or else shifting cannot be precisely adjusted any more.
- Align transmission properly to engine.
Note: If installed, place intermediate plate onto bushings.
Make sure that wires do not get pinched as transmission is docked at engine.
Check whether the torque converter is still properly installed and has not slid out of the converter housing toward the front:
- It must be possible to easily turn torque converter by hand without much force.
WARNING: In case of an incorrectly inserted torque converters the coupling plate of the torque converter or the ATF-pump will be destroyed, if the transmission is flanged to the engine.
- If the torque converter is difficult to move, check installation dimension once again, refer to Torque Converter - Service and Repair - Procedures Service and Repair
For 6 cylinder TDI engines
- Check whether brace -B- is still swung to side (arrow direction) before installing the transmission.
Continuation for all vehicles
- Install connecting bolts for engine/transmission.
Note: Some bolts also have a bracket or a Ground (GND) connection attached.
- Install multi-function Transmission Range (TR) switch -F125-.
- Slightly raise engine/transmission subframe at rear via VAG 1383A hoist.
- Install remaining connecting bolts for engine/transmission.
- Install front exhaust pipes, refer to Engine, Cooling and Exhaust - Exhaust System - Service and Repair - Procedures Service and Repair
- Install subframe, observe tightening sequence and alignment with master hole, refer to Body and Frame - Frame - Subframe - Service and Repair - Procedures [1][2]Service and Repair
- Only perform vehicle alignment if necessary, refer to Steering and Suspension - Alignment - Testing and Inspection - Procedures Testing and Inspection
- Install transmission supports at left and right with transmission mount, refer to Transmission Mount, A/T - Service and Repair - Procedures Service and Repair
- Remove bolt -A- after transmission is bolted to engine.
- Apply corrosion protection to contact surface between bolt -A- and oil pan.
Bolt torque converter to drive plate
For vehicles with hex bolts:
- Bolt torque converter to drive plate via 3 bolts using special tool V175 (turn crank shaft an additional 1/3 turn every time).
For vehicles with Torx bolts:
- Bolt 3 torque converter bolts to drive plate using respective Torx insert (turn crank shaft an additional 1/3 turn every time).
- Install starter, refer to Starting and Charging - Starting System - Starter Motor - Service and Repair - Procedures
- Install ATF lines to engine/transmission subframe.
- Install bracket for ATF-line.
- Slightly raise engine/transmission subframe at rear via VAG1383A hoist.
- Bolt in engine speed (RPM) sensor -G28- (arrow -B-) at front left of transmission (if installed).
- Connect connector for speedometer Vehicle Speed Sensor (VSS).
- Bolt drive axles to transmission flanges, refer to Drive Axles, Bearings and Joints - Axle Shaft Assembly - Service and Repair - Procedures Service and Repair
- Bolt in bolts at mounting bracket of selector lever cable, install selector lever cable and if necessary, adjust.
- Connect connector of multi-function Transmission Range (TR) switch -1-.
- Connect connector for transmission wiring harness and secure using securing lever -2-.
- Install shielding plate/selector lever cable
All-wheel-drive vehicles
- Bolt driveshaft to transmission flange, refer to Drive/Propeller Shafts, Bearings and Joints - Drive/Propeller Shaft - Service and Repair - Procedures
- Bolt heat shield -B- for driveshaft to Torsen differential cover (arrows) if installed.
- Install heat shield -A- above driveshaft.
Continuation for all vehicles
- Install bracket for noise insulation panel.
- Install noise insulation panel.
- Install front wheels.
- Connect battery Ground (GND) strap.
- Check adjustment of selector lever cable, refer to Shift Linkage, A/T - Shift Cable, A/T - Service and Repair - Procedures Service and Repair
- Check gear oil in final drive with transmission installed, refer to Differential, Automatic Transaxle - Testing and Inspection - Procedures Testing and Inspection
- Then check ATF level and top off, refer to Fluid, A/T - Testing and Inspection - Procedures Testing and Inspection
- After connecting battery, enter anti-theft code for radio.
- Fully close power windows to stop.
- Then activate all power window switches ("up") for at least one second to activate automatic window raising/lowering.
- Set clock to correct time.