Removing and Installing

Transmission removing and installing
Special tools and equipment





- 10-222 A Support
- 3094 Hose clamps
- 3282 Transmission support
- 3282/2 Adjustment plate
- 3300 A Engine support
- 3336 Transmission lifting beam





- VW 457/1 Support rails (modifying)
- 10-222 A/1 Support
- V.A.G 1331 Torque wrench
- V.A.G 1332 Torque wrench
- V.A.G 1383A Engine/transmission jack
- V/175 Socket

Modifying support rails VW 457/1





To secure support rail VW 457/1 to the subframe a new hole is required.
Dimensions given are in mm.
- Drill a 8.5 mm diameter hole (arrow) in support rail VW 457/1.

Removing
- Obtain radio code on vehicles with coded radio.
- Disconnect battery Ground strap.
- Remove engine cover.
- Remove battery.
- Remove battery carrier.





Remove air cleaner if fitted on left in engine compartment:
- Pull intake hose -1- and connector -2- off mass air flow meter.
- Pull off vacuum hose -3-.
- Remove bolts -4- and -5-.
- Remove air cleaner complete.
- Disconnect speedometer connector at transmission.





- Remove electrical connections -1- to -4- at transmission.
1. To the solenoid valves
2. To vehicle speed sensor -G68-
3. To multi-function transmission range switch -F125-
4. On transmission vehicle speed sensor -G38-
There are two types of sensor -G38-. Connection with and without cable.
- Remove wiring harness from retainer on transmission and place to one side.
- Remove bracket for power steering hose with retainer for wiring harness.





- Place selector lever in "P" and pry selector lever cable -1- off lever/selector shaft -4- with a screwdriver.

Note: Do not loosen bolt -2-.

- Remove circlip -3- at selector lever cable support bracket and remove selector lever cable.

Note: Do not kink selector lever cable.





- Disconnect battery Ground cable -1- from upper engine/transmission securing bolt.
- Disconnect electrical connections -3- and -4 on starter.
- Separate connector-2- and pull out of retainer.
- Remove wiring harness retainer on starter.
- Remove upper starter motor bolt.





- Clamp ATF cooler hoses with 3094 clamps and disconnect at ATF cooler.
- Seal off ATF cooler with clean plugs.
- Remove engine/transmission upper securing bolts.





- Install support bar 10-222 A with legs 10-222 A/1 and support engine/transmission in this position.
- Remove left front wheel bolts.
- Raise vehicle.
- Remove left wheel.





- Remove sound insulation tray -arrows-.





- Remove left sound insulation -arrows-.

Vehicles with TDI engine
- Remove pipe between charge air cooler and exhaust turbocharger.

Continued for all vehicles
- Remove right sound insulation.





- Remove ATF oil pan protective plate -arrows





- Remove bracket -1- for power steering pressure line from lower starter bolt -arrow-.
- Remove lower starter bolt
- Remove starter -2-.
- Remove right hand inner constant velocity joint protective cover from engine if installed.
- Disconnect drive shafts at transmission flanges.
- Raise right drive shaft and secure.





- Remove pendulum support -arrows-.
- Unclip cap for torque converter nuts cover.





- Remove nut -arrow- from torque converter (Qty. 3) using special tool V 175.
Turn crankshaft 120° further in each case.
- Turn steering to left lock.
- Mark installation position of ball joint bolts on left hand control arm and remove bolts.





- Remove bolts (arrows).





- Disconnect left coupling rod -1- from control arm and turn rod upward.
- Swing wheel bearing housing outward.
- Guide left drive shaft -2- out between subframe and transmission.
- Lift drive shaft and secure to suspension strut with wire.





- Remove left assembly mounting -2- hex bolts -arrows- from console -1-.
- Carefully tilt engine and transmission by lowering left-hand spindle approx. 60 mm on support bar 10-222 A.





- Remove left mount -1- from transmission -arrows-.
- Separate exhaust system at down pipe.





- Bolt support rail VW 457/1 to both pendulum support securing holes on subframe.
- Insert spacers totaling 6 mm between subframe and support rail VW 457/1.
-A- Qty. 2 hex bolts M8 x25
- Install support device 3300 A and tighten with bolt -B-.
- Tilt engine and transmission forward with support device 3300 A.





- Set up transmission support 3282.
Transmission support 3282 must be set up with adjusting plate 3282/2 for removing automatic transmission 01M.


The symbols on the adjusting plate indicate the supports required.





- Move jack V.A.G 1383 A with support 3282 under transmission and support it.





- Place safety support pin on oil pan and secure to transmission housing (arrow).





- On vehicles with triple roller drive shaft turn transmission flange to right so that flat -arrow- is vertical.
- Remove lower engine/transmission connecting bolt.
- Press transmission off engine, pressing torque converter out of drive plate while doing so.
- Press torque converter against ATF pump.
- Lower transmission slightly.
- Guide power steering pressure line past transmission.
- Tilt transmission using transmission jack spindle and while lowering ensure cover (wheel housing side) is guided closely past wheel housing.
- Swivel transmission and carefully lower.

Note: Ensure that the right joint flange does not contact the engine or the support device 3300 A and that the multi-function TR switch does not contact the subframe.

- Secure torque converter to prevent it falling out.

Installing
Installation is performed in the reverse order of removal.
When installing the torque converter, ensure that both drive pins engage in the ATF pump inner wheel recesses.
- Before installing, ensure that dowel sleeves are correctly located.
- When installing gearbox, observe torque converter contact impression on drive plate.
- Replace selector cable anchorage locking washer.
- Check selector lever cable adjustment, adjust if necessary.
- Check and top up ATF level.
- Perform On Board Diagnostic (OBD) and initiate basic setting.

Tightening torques
Torque converter to drive plate - 60 Nm
Transmission to engine bolt M12 - 80 Nm
Transmission to engine bolt M10 - 60 Nm
Transmission to crankcase/engine M10 - 25 Nm





Transmission to body
- Replace bolts
Bolts -A- 60 Nm + 90°
Bolts -B- 40 Nm + 90°





Rear transmission mounting
- Replace bolts
Bolts -A- 20 Nm + 90°
Bolts -B- 40 Nm + 90°

Note: Install engine/transmission mountings stress free.