2.5L Engine

Transmission, Removing

- Before removing, print out the diagnostic protocol for the vehicle, if possible. Affix the protocol onto transmission before sending it back in the usual way.

Short Description

The transmission is remove downward by itself. The engine remains in the vehicle.

Remove the battery, the battery tray, the engine cove with air filter from above. The engine with transmission are then supported so that the transmission mount bracket can be removed.

Remove the noise insulation and the drive axles from underneath. Lower the transmission using the transmission jack.

• The subframe is not removed.

Special tools, testers and auxiliary items required

• Engine-/Gearbox Jack (V.A.G 1383 A)

• Socket SW15 (V/175)

• Transmission Support (3282)

• Wedge Tool (T10161)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Adjusting Plate - 09D Trans. (3282 /36)

• Engine Support Bridge (10 - 222 A)

• Hose Clamps Up to 25 mm Dia. (3094)

• Tensioning Strap (T10038)

• Engine Support Basic Set (T40091)

Procedure

- Move the selector lever into the "P" position.

- Turn off the ignition and disconnect the battery ground cable.

- Remove the engine cover with air filter.

- Disconnect the hoses - arrows - and remove the intake hose from the throttle valve.






- Remove the battery, the battery tray bolts - arrows - and tray.






- Disconnect the cable - arrows 1 - and then remove it from the cable bracket - arrow 2 -.






• Do not use pliers because the tabs on the cable bracket could break off.

• Do not bend the selector lever cable.

- Pry the cable - 1 - off the selector shaft lever - 3 - using a open end wrench - 2 -.






- Install the hose clamps up to 25 mm dia. (3094) on the hoses and remove the hoses form the Automatic Transmission Fluid (ATF) cooler.






- Disconnect the following:

• Multifunction switch connector

• Starter connector

- Remove the cable bracket - 1 - from the starter stud bolt - arrow -.






- Remove the bolt from the top of the starter.

- Remove the upper engine to transmission bolts.

- Remove the plenum chamber cover.

- Remove the radiator grille.

So that engine and transmission can be supported:

- Remove the wires - 1 - from the transport strap - 3 -.






- Remove the transport strap - 3 - from the engine - 2 - and pull it out of the lifting eye - arrow -.

- Attach one shackle (10-222 A/12) to this lifting eye.

- Install the engine support bridge (10-222 A) and support the engine and transmission. Do not lift.






1. Adapter (T40091/3)

2. Bar (T40091/1)

3. Support bracket (10-222 A/31-1)

4. Shackle (10-222 A/12)

5. Support bracket (10-222 A/31-4)

6. Support bracket (10-222 A/31-3)

7. Engine support adapter (10-222 A/3)

8. Adapter (10-222 A/7)

9. Support bracket (10-222 A/31-2)

10. Bracket with spindle and hook (10-222 A/10)


- Use the (10-222 A/7) (- 8 -) to lengthen the right bracket with spindle and hook (10-222 A/10) (- 10 -).

The hook points downward and will be secured to the cylinder block later.

The left drive axle must be removed later in the procedure.






- With the vehicle still resting on its wheels, loosen the left front drive axle bolt - arrow - a maximum of 90°, otherwise the wheel bearing will be damaged.

- Raise the vehicle and remove the front wheels.

- Remove the noise insulation.

- Remove the left front wheel housing liner.

- Remove the brackets and the power steering lines from the transmission.

- Separate the exhaust system at the double clamp and remove the exhaust pipe bracket from the subframe.

- Remove the ball joint to control arm nuts - arrows - on both sides.






- Remove the right drive axle heat shield bolts - arrows - and shield, if equipped.






- Remove both drive axles from the transmission.






- Remove the left drive axle from the vehicle.

- Lift the right drive axle up as far as possible and secure it.






- Disconnect the connectors - 1 and 2 - from the transmission.






- Remove the connector from the bracket under the starter - 1 - and then disconnect it.






- Remove the bracket from the lower starter bolt.

- Remove the bottom starter bolt and remove the starter.

- Remove the pendulum support, first remove bolt - A -, then bolts - B -.






- Turn the cap - 1 - in the - direction of the arrow - and remove it.






- Remove the converter nuts using the socket SW15 (V/175).






• Carefully rotate the engine further!

- Secure the adapter (10-222 A/7) to the cylinder block.






Tension the right spindle one turn (additional turns are not necessary).

- Support the engine and transmission with the left spindle. Do not lift.

- Remove the ground cable from the transmission mount bracket - A -, if equipped.






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






- Remove the transmission mount bracket - A -. Using the spindles on the engine support bridge (10-222 A) , lower the engine and transmission slightly.

Four turns should be sufficient.

- Remove the lower bolts between the engine and the transmission.

- For your personal safety, leave one bolt installed that is easily accessible.

- Support the transmission using the engine-/gearbox jack (V.A.G 1383 A) , the transmission support (3282) and the adjusting plate - 09D trans. (3282/36) before removing the last bolt.






- Secure the transmission to the transmission support (3282) using the nut - 1 - on the stud bolt.

- Remove the last bolt.

- While pressing the torque converter off the drive plate, separate the transmission from the engine.

- Guide the transmission past the power steering line and past the subframe when lowering it. Adjust the transmission support (3282) slightly, if necessary.

• Be careful not to damage the connector on the front of the transmission during removal and installation, for example, by coming in contact with the power steering line. Replace the wiring harness in the transmission if the connector gets damaged. Refer to => [ Valve Body Overview ] Valve Body Overview.

• Be careful of the torque converter. It must be removed together with the transmission. Secure the torque converter with wire - A - to prevent it from falling out.






• The cable bracket and the selector lever cable bracket must be replaced when installing a new transmission.