Transmission, Removing
Transmission, Removing
Special tools, testers and auxiliary items required
• Support channels (VW 457) (modifying => [ Support Channels VW 457/1, Modifying ] Support Channels VW 457/1, Modifying)
• Engine support bridge (10 - 222 A)
• Adapter (10 - 222 A /3)
• Adapter (10 - 222 A /8)
• Shackle (10 - 222 A /12)
• Transmission support (3282)
• Adjustment plate (3282/39)
• Engine support device (3300 A)
• Transmission support jig (3336)
• Engine/transmission jack (V.A.G 1383 A)
• Torque wrench 5 to 50 Nm (V.A.G 1331)
• Torque wrench 40 to 200 Nm (V.A.G 1332)
• Tensioning strap (T10038)
• Grease (G 000 450 02)
• Grease for clutch plate splines (G 000 100 )
- First determine whether a coded radio is installed. In this case, determine the anti-theft coding.
- Disconnect battery ground (GND) cable with ignition switched off.
- Remove engine cover.
- If power steering refill tank is located at battery tray, remove it from battery tray, do not kink hoses while doing so.
- Tie refill tank to lock carrier.
- Remove battery and battery tray.
- Disconnect intake air duct - 1 - and connector - 2 - from Mass Air Flow (MAF) sensor (G70).
- Remove bolts - 3 - and - 4 -.
- Remove complete air filter.
- Remove lock washer - arrow 1 - for shift cable from transmission shift lever - A -.
- Remove locking washer - arrow 2 - for selector cable from actuator lever - B -.
- Pull off selector cable and shift cable from pins.
- Pull off lock washer - arrow 3 - from relay lever - B - and remove relay lever.
- Remove transmission shift lever - A -, to do this remove nut - arrow 4 -.
- Remove cable mounting bracket from transmission - arrows -.
- Tie up shift cable and selector cable.
- Remove bracket - B - from transmission and disconnect it from hose/line assembly - A -.
- Remove transmission support - arrows A -.
- Remove slave cylinder - arrow B - and lay to side. Secure slave cylinder with wire, do not disconnect line.
• Do not depress clutch pedal.
- Remove ground (GND) cable from connecting bolt at top of engine/transmission.
- Disconnect connector for backup lights - arrow 1 -.
- Disconnect connector - arrow 2 - and wire - arrow 3 - from starter.
- Then remove upper securing bolt on starter.
- Remove upper connecting bolts for engine/transmission.
- Remove end plate of plenum chamber.
- Remove wires - 1 - from transport strap - 3 -.
- Remove bolts - 2 - and remove transport strap - 3 -.
- Engage shackle (10 - 222 A /12) in lifting eye of engine - arrow -.
- Attach engine support bridge (10 - 222 A) in conjunction with adapter (10 - 222 A /8) and adapter (10 - 222 A /3).
- Do not place adapter (10 - 222 A /8) on attachment bolts for fender/front part.
- Lay tensioning strap (T10038) behind pins - arrows - around exhaust manifold and engage into right spindle.
- Hook left spindle in shackle (10 - 222 A /12).
- Take up weight of engine/transmission assembly on spindles.
- Raise vehicle.
- Remove center, left and right sections of sound insulation below engine/transmission
- All wires must be removed from transmission.
- Remove starter
- Remove protective cap for drive axle from engine, if present - arrows -.
- Remove drive axles from drive flanges and tie up as far as possible, do not damage protective coating.
- Remove bolt - 1 - and remove small cover plate - 2 - for flywheel.
- Remove front exhaust pipe bracket from subframe - arrows -.
- Disconnect exhaust system behind front exhaust pipe.
- Tie up exhaust system.
• Flex joint in front exhaust pipe must not be bent more than 10 degrees, otherwise it may be damaged.
- Remove pendulum support - arrows A - and - arrows B -.
- Remove bolts - arrows - of left transmission mount.
- Bring engine/transmission assembly into tilt position. To do so, lower via spindles of engine support bridge (10 - 222 A ).
• Pay attention to all wires when lowering transmission.
• Make sure, attachment bolts - arrows - for transmission bracket - A - are accessible.
- Remove transmission bracket - A - - arrows -.
- Remove fan and, if present, auxiliary fan.
- Bolt in support channels (VW 457/1) in threaded holes for attachment bolts/pendulum support to subframe.
- Spacer discs with a total thickness of 6 mm must be inserted between subframe and support channel (VW 457/1).
A M8 x 25 hex bolts (2x)
• Instead of support channels (VW 457/1), the support (T10036) can also be used.
- Install engine support device (3300 A ) and tighten - arrows -.
- Carefully push engine/transmission assembly toward front.
• While shifting engine/transmission assembly, pay attention to all lines.
Transmission support (3282) is equipped with adjustment plate ( 3282/39) to remove transmission " 0A4".
- Insert transmission support (3282) in engine/transmission jack (V.A.G 1383 A).
- Align transmission support arms to correspond with holes in adjustment plate.
- Bolt in attachments - A - and - C -, as depicted on adjustment plate.
- Place engine/transmission jack under vehicle, arrow symbol - B - on adjustment plate points in direction of travel.
- Align adjustment plate parallel to transmission and lock safety support on transmission.
- Bolt in pin (3282/39) in bore for mounting bolt of pendulum support to transmission.
- Remove lower connecting bolts for engine/transmission.
- Press transmission off alignment bushings and carefully swing toward subframe.
- Carefully lower transmission, guide with right drive flange - A - in area of flywheel and with left drive flange - B - in area of subframe, as shown.
- Change position of transmission by lowering via spindles of transmission support (3282).
• Pay attention to all wires when lowering transmission.