Removing gearbox, 2.5 l engines — VW

🧭 Before you start

Fits: platform codes A32, A33

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: 3093, T40091/1, locking pin

Don't miss

• Do not use any pliers, otherwise securing tabs on cable support bracket could break off.Do not bend or kink selector lever cable.
• Mark coolant hoses to ATF cooler to prevent interchanging during installation.
• Take up weight of engine and gearbox via spindle10 - 222 A /11(item 11). Do not raise.

📋 Procedure

1. Move selector lever to »P« position.
2. With ignition switched off, disconnect battery earth strap Electrical system27Battery; Disconnecting and connecting battery.
3. Remove engine cover panel with air filter 24Air filter; Removing and installing air filter housing.
4. Pull off hoses (arrows) and remove intake hose from throttle valve unit.
5. Unclip automatic gearbox control unit J217(3) at top of bracket (7) and pull off upwards.

6. Release connector (2) and pull off automatic gearbox control unit J217.
7. Unscrew bolts (1) and (6).
8. Place bracket (7) with servo oil reservoir to one side. When doing this, observe electrical wiring (4) and (5).
9. Remove battery and battery tray Electrical system27Battery; Removing and installing battery tray.
10. In order to remove selector lever cable from gearbox, first release cable (arrows 1) and then remove it from cable support bracket (arrow 2). [Note: Do not use any pliers, otherwise securing tabs on cable support bracket could break off.Do not bend or kink selector lever cable.]
11. Lever off selector lever cable (3) from selector shaft lever using an open jaw spanner (1), for example.
12. Pull connector (4) off multifunction switch F125 and lay electrical wiring on bracket (2) to one side.
13. Remove earth wire from securing bolt (3) for gearbox bracket.
14. Disconnect electrical wiring (1) and (2) on starter and place to one side.
15. Remove bracket (1) from upper starter motor bolt (arrow).
16. Remove upper starter motor bolt. [Note: Mark coolant hoses to ATF cooler to prevent interchanging during installation.]
17. Clamp off coolant hoses to ATF cooler using hose clamps3094 and 3093.
18. Open spring-type clips (A) and pull coolant hoses (B) and (C) off ATF cooler.
19. Seal coolant hoses and connection unions using suitable bungs/plugs from engine bung setVAS 6122.
20. Unscrew upper bolts (arrows) connecting gearbox to engine using double hexagon U/J socket (A).
21. Remove plenum chamber cover General body repairs, exterior50Plenum chamber cover; Removing and installing plenum chamber cover.
22. Remove cables (1) from transportation bracket (3).
23. Unbolt transportation bracket (3) from engine (2) and pull out of eye (arrow).
24. Attach a shackle10 - 222 A /12 in »this« eye.
25. Unscrew bolts (arrows) for retaining brackets on left and right of lock carrier.
26. Unscrew lower supports from adapters10 - 222 A /28 and replace with supports 10-222 A /28-2.
27. Place adapters10 - 222 A /28 with supports 10-222 A /28-2 on lock carrier at left and right and screw on using threaded holes for lock carrier retaining brackets (arrows).
28. ⚠ A 2nd mechanic is needed to place support bracket10 - 222 A on the vehicle in order to prevent the support bracket from tipping. — First push swivel joints(item 2) onto square tube10 - 222 A of support bracket.
29. Place 10-222 A on suspension strut turrets with the aid of a 2nd mechanic to prevent it from tipping.
30. T40091/1 Push (item 5) on left and right from front through 10-222 A /28(item 6) and fit swivel joints T40093/4(item 4) on each side.
31. In addition, place hook10 - 222 A /10(item 7) on right square tube T40091/1.
32. Push hole rail T40091/2(item 9) with support T40093/5(item 10) into swivel joints T40093/4(item 4).
33. Insert locking pin in hole rail T40091/2(item 9) and secure with split pins.
34. Tighten all threaded connections of support bracket by hand. When doing this, adjust support bracket via adapters10 - 222 A /28 so it is parallel in height.
35. Extend right hook10 - 222 A /10(no. 7) with adapter10 - 222 A /7(no. 8).
36. Hook in left spindle10 - 222 A /11(item 11) in shackle10 - 222 A /12(item 12).
37. Depress brake pedal to remove bolt for left drive shaft (arrow) (second mechanic required). [Note: Do not lower vehicle onto ground after doing this Running gear, axles, steering40Removing and installing drive shafts.]
38. Raise vehicle and remove front wheels.
39. Remove noise insulation tray.
40. Remove front left and front right wheel housing liner General body repairs, exterior66Wheel housing liner; Removing and installing wheel housing liner.
41. Separate exhaust system at double clamp and unbolt exhaust pipe bracket from subframe 26Exhaust pipes/silencers; Assembly overview - silencer.
42. Unbolt (arrows) suspension link from wheel bearing housing on both sides.
43. If present, remove heat shield above right drive shaft (arrows).
44. Press right drive shaft from gearbox Running gear, axles, steering40Drive shaft: Removing and installing drive shafts.
45. Remove left drive shaft Running gear, axles, steering40Drive shaft; Removing and installing drive shafts.
46. Raise right drive shaft as high as possible and secure in this position.
47. Now pull electrical connectors (1) and (2) off gearbox.
48. Unscrew securing clamps for power steering line on gearbox (arrows).
49. Pull connector beneath starter (1) out of retainer and separate.
50. Unbolt retainer from lower starter bolt.
51. Unscrew bottom starter motor bolt and remove starter Electrical system27Starter; Removing and installing starter.
52. Turn cap (1) in (direction of arrow) and remove.
53. 6 Remove (torque converter nuts) with insertV/175.
54. To do this, turn engine with wrench T03003 60° for each nut in engine direction of rotation (arrow). [Note: If all 6 nuts are not removed from the torque converter, the torque converter will be pulled out when the gearbox is removed from the engine!To loosen the nuts of the torque converter, counterhold with wrench T03003 on belt pulley/vibration damper.]
55. Remove retainer for selector lever cable on gearbox.
56. Remove pendulum support, first bolt (A) and then bolts (B).
57. Hook adapter10 - 222 A /7 into engine block.
58. Take up weight of engine and gearbox via spindle10 - 222 A /11(item 11). Do not raise.
59. Remove bolts (2) connecting gearbox mounting to gearbox bracket (A) and bolts (1) connecting gearbox bracket to gearbox.
60. Now, remove gearbox bracket (A). To do this, lower engine and gearbox slightly via spindles of support bracket10 - 222 A.

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