Removing and installing gearbox - vehicles with hybrid drive — VW

VW
Touareg
2010
Touareg
2015
Power transmission
8-speed automatic gearbox 0C8
Edition
12.2014
Removing and installing gearbox - vehicles with hybrid drive
Brief description
In these vehicles, the gearbox is removed separately downwards. Engine with electric drive motor remain in the vehicle.
Special tools and workshop equipment required
Support bridge
30 - 211 A
Removal lever
80 - 200
Engine and gearbox jack
V.A.G 1383 A
Adapter
T40058
Depth gauge
VAS 6082
Engine plug set
VAS 6122
Step ladder
VAS-5085
Gearbox support
T40173
with
support pads
VAS 6131/14-1
Not illustrated:
gearbox support
T40173/1
Caution
WARNING
Before using
gearbox support
T40173
, it is essential to verify that it is the current version.
Older versions of the support must not be used and must be exchange for the current version.
Identification of current version:
Beginning with the current version, components shown in
red
arrows
are chrome-plated yellow.
If the support does not conform to the specification, proceed as follows:
German market: Contact the company Matra to arrange an exchange.
All markets except Germany: Contact your importer to arrange an exchange.
Modify
gearbox support
T40173
as follows:
Set up
gearbox support
T40173
with
adjustment plate
T40173/1
. To do so, attach
gearbox support
T40173/1
between the rigid supports
1
and the bars
arrows
.
Removing
WARNING
High voltage on high-voltage system of hybrid vehicle. Danger of electric shock! Following procedure also requires work on high-voltage system. De-energise high-voltage system now
Electric drive
Rep. gr.
93
De-energising high-voltage system
.
Note
Removing gearbox requires
stepladder
VAS-5085
.
Remove cover from engine.
Procedure for disconnecting batteries must strictly be followed.
With ignition switched off, disconnect battery earth strap
Electrical system
Rep. gr.
27
Disconnecting and connecting battery
.
Remove front and rear propshafts
Transfer box and final drives
Rep. gr.
39
Removing and installing propshafts
.
Remove catalytic converter on left and right
Rep. gr.
26
Removing and installing parts of exhaust system
.
Remove heat shield on right from gearbox.
Remove bolts
1, 2
and pull ATF pipes off gearbox. Catch oil which runs out.
Use suitable plugs from
engine bung set
VAS 6122
to seal ATF pipes.
Disconnect electrical connectors
1, 2, 3
from gearbox.
Pull connector
1
off
supplementary hydraulic pump 1 for gearbox oil
V475
2
.
Pull connector
1
off
multifunction switch
F125
2
.
Separate selector lever cable at ball head
1
using
removal lever
80-200
and remove lock washer
3
.
Note
A securing clip which has been removed is not allowed to be installed again. Always renew securing clip.
Do not bend or kink selector lever cable.
Item 2
can be disregarded.
Insert guide pin of adapter
T40058
as follows.
Large diameter
arrow 1
points towards engine.
Small diameter
arrow 2
points towards adapter.
Brace crankshaft using
adapter
T40058
and offset ring spanner in order to unscrew bolts for drive plate.
Note
Only turn crankshaft in direction of engine rotation
arrow
.
Remove sealing cover
1
. Working through the opening in the gearbox, remove 3 securing nuts for torque converter
arrow
. Turn crankshaft through 120° for each.
Remove transfer box
Transfer box and final drive
Rep. gr.
34
Removing and installing transfer box
.
Retaining tool
VW 785/1 B
required for removing transfer box must now be removed again.
Secure support bracket for engine on body
Rep. gr.
10
Supporting engine in installation position
.
Support engine and gearbox from above, remove load from
retaining tool
VW 785/1 B
by means of spindle and remove.
Position
engine and gearbox jack
V.A.G 1383 A
with modified
gearbox support
T40173
against bottom of gearbox and, if possible, secure gearbox with belt.
Remove load from engine and gearbox at top using support bracket.
Lower gearbox slightly with
engine and gearbox jack
V.A.G 1383 A
.
Unbolt ATF pre-heater
arrows
from gearbox.
Remove catalytic converter bracket on right
A
.
Pull bleed hose
B
off retaining clip.
Remove catalytic converter bracket on left
A
.
Note
At the same time, use catalytic converter bracket on left and right to remove 2 connecting bolts each from gearbox/electric drive motor.
Support engine at top.
Unscrew remaining connecting bolts
1 … 10
from gearbox.
Force gearbox off electric drive motor.
Note
During removal, it is essential to make sure that torque converter does not slip out of gearbox.
Remove gearbox downwards using
engine and gearbox jack
V.A.G 1383 A
.
After gearbox has been removed, secure torque converter with
support bridge
30-211 A
to prevent it from falling out.
Installing
Install in the reverse order of removal, observing the following:
If ATF is dirty or if an exchange gearbox is to be installed, clean ATF cooler and ATF lines
Chapter
.
Threads of bolts secured with locking fluid must be cleaned with a wire brush. Then insert bolts with
locking fluid
AMV 185 101 A1
.
Use a thread chaser to clear residual locking fluid from all threaded holes into which self-locking bolts are to be screwed. Otherwise there is a danger of bolts shearing when subsequently being removed.
Always renew self-locking bolts and nuts.
Reassemble all electrical connections, lines, hoses and connectors that were disconnected during removal.
Before installing gearbox, ensure that torque converter seats correctly in gearbox
Chapter
.
Check installation dimension
a
Fig.
Before gearbox is installed in electric drive motor, check that dowel sleeves for centring electric drive motor/gearbox are not missing,
arrows
, and insert if necessary.
When joining electric drive motor and gearbox together, make sure that studs of drive plate are aligned with converter sockets.
Caution
If engine and gearbox are brought together with force because the torque converter is improperly fitted, both gearbox and torque converter will be damaged.
Therefore, when securing gearbox to electric drive motor, check frequently that the torque converter
»moves freely«
and is not being pinched.
Overview of connecting bolts on gearbox and electric drive motor.
Torque setting 30 Nm and then turn 90° further. Renew bolts.
Working through the opening in the gearbox, tighten 3 securing nuts for torque converter
arrow
. Turn drive shaft through 120° for each. Insert sealing cover
1
.
Torque setting 60 Nm.
Bolt ATF pre-heater
arrows
onto gearbox.
Remove plugs and push ATF lines into gearbox to stop.
Install bolts
1.2
Chapter
.
Carefully press ball head
1
of selector lever cable onto selector shaft lever. Do not bend selector shaft lever or selector can no longer be precisely adjusted.
Renew securing clip
3
.
Check selector lever cable adjustment and adjust if necessary
Chapter
.
Continue assembly in reverse order of dismantling.
After installing, check ATF level and top up if necessary
Chapter
.
Specified torque
ATF pre-heater to gearbox
20 Nm