Removing and installing gear detection sensor G604 — VW

Removing and installing gear detection sensor
G604
Special tools and workshop equipment required
Engine strut
T50015
Torque wrench
V.A.G 1783
Torque wrench
V.A.G 1332
Engine and gearbox jack
V.A.G 1383 A
Removing
Shift gearbox to
“N” position.
Unbolt propshaft (A) from gearbox flange and secure propshaft to body using e.g. baling wire.
Loosen securing clamp on exhaust pipe (1) and press exhaust system (2) off front exhaust pipe (arrow).
Note
Do not move exhaust filter, or the exhaust pipe will leak (repair group 26: Exhaust system).
Securing clamp (1) must always be renewed.
Position engine and gearbox jack
V.A.G 1383 A with gearbox support
V.A.G 1359/2 under gearbox.
Remove bolts (1) and (2) for gearbox carrier.
Note
Mark the installation position of the gearbox carrier.
Depending on construction, there may be four securing bolts (2) for the gearbox mounting.
Lower gearbox using engine and gearbox jack
V.A.G 1383 A far enough that securing bolts (2) for gear detection sensor
G604 (1) can be removed.
Attach engine strut
T50015 to available holes (arrow).
Note
Depending on construction, other components associated with optional equipment may be attached to the securing points (arrows) for the engine support
T50015.
These additional components must be removed according to the instructions in the respective workshop manuals.
Turn spindle on engine strut
T50015 to bring engine to installation position.
Caution
It is not permitted to support the engine between the sump and the steering box.
This manner of support can lead to damage to the steering box.
As a consequence, hydraulic fluid leaks may develop in the steering box, leading to the failure of power steering.
To avoid this, use engine strut
T50015 to support the engine.
Unclip connector (3) from gear detection sensor
G604 (1) and remove securing bolts (2).
Installing
Install in reverse order of removal, observing the following:
Note
The sealing surface of the gear detection sensor
G604 must be free of oil and grease.
Apply sealant
Electronic parts catalogue to sealing surfaces of gearbox housing and fit gear detection sensor
G604.
Place gearbox carrier in its previously marked position.
Teach gearbox shift position to gear detection sensor
G604
Vehicle diagnostic tester.
Specified torque (repair group 26: Exhaust pipes/silencers). (repair group 39: Propshaft)
Component
Specified torque
Securing bolts for gear detection sensor
G604
3 Nm
Securing bolts for propshaft safety bar
100 Nm
Securing bolt for gearbox carrier
58 Nm