Transmission, Removing and Installing
Removing
Special tools, testers and auxiliary items required:
^ Engine-/Transmission lifter V.A.G 1383 A.
^ Transmission support 3282
^ Centering plate3282/12
^ Drip tray VAG1306
- Obtain radio code on vehicles with coded radio.
- With ignition switched off disconnect battery Ground strap.
- Loosen bolts (arrows) and remove engine cover panels (arrows -A- through -C-).
- Detach air intake duct. To do this, pull off retainer catch -1-, loosen clamps -2- and unscrew bolts -3-.
- Remove coolant system expansion reservoir and lay to one side.
- Unplug connector for lambda probe on left (arrow -2-) and move wire for lambda probe clear.
- Unplug connector for lambda probe on right -1- and move wire for lambda probe clear.
- Unscrew two bolts securing heat shield -2- on exhaust pipe (right and left).
- Unscrew nuts -3- on exhaust pipe (right and left).
- Unscrew engine/transmission securing bolts accessible from above.
- Remove noise insulation (arrows).
- Unbolt bracket for noise insulation (arrow).
- Unbolt heat shields from transmission above left and right drive axles (arrows).
- Unbolt left and right drive axles -1- from transmission, lift clear and tie in position.
Note: Take care not to damage protective coating on drive axles.
- Loosen exhaust system clamps and push clamps towards the rear.
- Remove heat shield for driveshaft from cover for Torsen differential (arrows).
- Unbolt driveshaft -1- from transmission and rest it on heat shield -2-.
- Secure driveshaft to fuel pipe bracket -3- with wire (arrow).
- Remove bolts (arrows) and remove transverse mount-A-.
- Unscrew and remove bolts -1- and -2- on right and left and remove support-A-.
- Lower subframe at rear and place spacer (e.g. wedge of wood) in gap.
^ a - max. 50 mm
- Unscrew bolts -1- and -2- and remove right and left transmission supports from transmission and subframe together with bonded rubber mountings.
- Loosen clamp -3-, lift heat shield -2-slightly and unscrew remaining nuts -5-.
- Lift heat shield -2- and pull out front exhaust pipe together with catalytic converter -4-.
- Note that lambda probe -1- and lambda probe wire have to be guided through opening in heat shield -2-.
Note: Avoid excessive bending of the flexible pipe connection (decoupling element) on the front exhaust pipe. The angle between the catalytic converter and the front exhaust pipe must not exceed 10°, otherwise the flexible connection will be damaged.
- Lift the transmission for access to the two lower bolts securing engine to transmission (= A34-0173 below).
A - Axle stand
B - V.A.G1 383A
- Unscrew two bolts securing transmission to engine (arrows).
Note: The two hexagon socket head bolts M10 x 60 must be replaced by new hexagon bolts M10 x 55 (Part No. N104684 01) so that the two bolts (arrows) can be tightened with a torque wrench after installing the transmission.
- Lower transmission again slowly.
- Remove engine speed sender-G28 from left-hand side of transmission (arrow) and place to one side.
- Pull connector off sender for speedometer.
- Pull off connector on reversing light switch.
- Unbolt the starter and push it as far as it will go towards the front.
Note: Do not disconnect cables at starter.
- Unbolt connecting rod -2- for selector rod on right-hand side of transmission.
- Remove hexagon socket head bolt from push rod -1-.
Note: Washers, which may have been installed between the pushrod and transmission (arrow) must be reinserted during reassembly.
- Unscrew nut -1- and pull selector rod lever -2- off transmission selector shaft.
- Remove all connecting bolts for engine/transmission from below, except for one bolt for securing.
- Set up transmission support 3282 with adjustment plate 3282/12 for removal of manual transmission 01E (all-wheel drive) and place on transmission jack V.A.G 1383 A.
A - Attachments
Notes:
^ The positions for the attachments are indicated by symbols (A). Arrow -B- points in the direction of travel.
^ Adjustment plate 3282112 can only be fitted in one position.
- Run transmission jack V.A.G 1383 A with transmission support 3282 in under the transmission and take up the weight of the transmission.
- Secure transmission to transmission support 3282.
Note: If transmission support 3282 is not available, the transmission can be removed and installed using transmission jack V.A.G 1383 A.
- Remove the last remaining engine/transmission securing bolt.
- Press transmission off dowel sleeves and lower carefully with transmission jack V.A.G 1383 A just far enough for access to the slave cylinder.
Note: When lowering transmission ensure hydraulic pipe/hose to slave cylinder is not damaged.
- Remove bolt (arrow) and take out slave cylinder from the rear. Do not open the pipe/hose system.
Note: Do not depress clutch pedal after removing slave cylinder.
- Lower transmission completely.
Note: When lowering transmission ensure there is sufficient clearance to drive axles.
Installing
Installation is carried out in the reverse order, when doing this note the following:
- Always replace all seals and gaskets.
- Always replace all self-locking nuts.
- Check whether dowel sleeves for aligning transmission with engine are in the engine flange. Insert if necessary.
- Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease G000100 to the splines. Do not grease guide sleeve.
- Check clutch release bearing for wear and replace if necessary.
- Coat area -a- of collar with lithium grease G 052 150 A2 before mounting slave cylinder into transmission housing.
- Coat contact surface for clutch slave cylinder push rod with a thin layer of copper grease, e.g.Z381 351TE.
- On vehicle with V6 bi-turbo engine, fit intermediate plate on dowel sleeves on engine flange.
- The two hexagon socket head bolts M10 x 60 must be replaced by new hexagon bolts M10 x 55 (Part No. N104684 01) so that the two bolts (arrows) can be tightened with a torque wrench after installing the transmission.
- Before installing transmission, tie electrical wiring off to one side so that it cannot be trapped between the engine and the transmission.
- Lift transmission until clutch slave cylinder with bracket for pipe/hose can be installed (arrow).
- Align exhaust system free of stress.
- Before installing, use a tap to clean threads in drive flange for driveshaft on transmission to remove traces of locking compound.
- Replace gaskets on drive axles and on front of driveshaft.
- Bolt on driveshaft.
- Check adjustment of selector rod and push rod; readjust if necessary.
- Check oil level in transmission.
- After connecting battery, enter anti-theft code for radio
- Close windows fully using electric window switches.
- Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic one-touch function.
- Set clock to correct time.
Vehicles with 6-cyl. bi-turbo engine
Dowel sleeves -A- for aligning.
1. The two hexagon socket head bolts M10 x 60 must be replaced by new hexagon bolts M10 x 55 (Part No. N104684 I) so that the two bolts -4- can be tightened with a torque wrench after installing the transmission.
Tightening Torques Part 1 of 7
Tightening Torques Part 2 of 7
Tightening Torques Part 3 of 7
Tightening Torques Part 4 of 7
Tightening Torques Part 5 of 7
Tightening Torques Part 6 of 7
Tightening Torques Part 7 of 7