Removing gearbox, 4x4 vehicles with all-wheel drive — VW

Removing gearbox, 4x4 vehicles with all-wheel drive
Special tools and workshop equipment required
Fitting tool
3046
Engine support
T50015
Lifting tackle
2024 A
Support bridge
30 - 211 A
Removal lever
80 - 200
Engine bung set
VAS 6122
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Engine and gearbox jack
V.A.G 1383 A
Or
engine and gearbox jack
VAS 6931
Note
Comply with rules for cleanliness when working on gearbox
Chapter
.
Observe repair instructions
Chapter
.
Observe safety precautions
Chapter
.
Seal open lines and connections using clean plugs from
engine bung set
VAS 6122
.
Raise vehicle
Maintenance
Booklet
11
.
If fitted, remove engine/gearbox guard
General body repairs, exterior
Rep. gr.
66
Engine/gearbox guard; Removing and installing engine/gearbox guard
.
Remove starter
Electrical system
Rep. gr.
27
Starter; Removing and installing starter
.
Reinstall engine mounting after the starter has been removed. Otherwise the engine may tip over during subsequent repair work.
Remove front silencer
Rep. gr.
26
Exhaust pipes/silencers; Removing and installing front silencer
.
Remove front propshaft
Rep. gr.
39
Propshaft; Removing and installing propshaft
.
Note
It is not necessary to remove the rear propshaft completely.
Unscrew bolts
arrows
for rear propshaft
1
and remove propshaft from flange
2
.
Tie up propshaft
1
at a suitable location using wire
arrow
.
Unlock connector
arrow
by turning it anti-clockwise in
direction of arrow
.
Unclip wiring harness from gearbox
1
arrows
and lay to side.
Caution
Do not loosen the bolt on the selector lever cable. Otherwise the selector mechanism must be readjusted.
Pull securing clip
arrow
in
direction of arrow
off selector lever cable
1
and out of guide.
Press selector lever cable on ball head
arrow
off gearbox using
removal lever
80-200
. Then pull cable
1
in
direction of arrow
out of guide and lay to side.
Remove particulate filter bracket
1
from gearbox. To do this, unscrew bolts
arrows
.
Note
Only turn crankshaft in direction of engine rotation
arrow
.
Turn crankshaft
1
using an offset ring spanner
arrow
until the torque converter bolts are accessible.
Note
Counterhold crankshaft with ring spanner when loosening torque converter.
The torque converter is secured with three bolts. Therefore turn crankshaft by 120° to access the bolts one after another.
Unscrew bolts
arrow
from torque converter
1
.
Note
Catch oil which runs out. Seal ATF lines and gearbox using clean plugs from
engine bung set
VAS 6122
.
Unscrew bolt
1
for ATF lines
arrows
from gearbox and disconnect ATF lines.
Unscrew securing bolt
arrow
for ATF lines
1
.
Unscrew bolt securing ATF double line
1
from bracket
2
and lay line together with clamp
arrow
to side.
Secure
adapter
2024 A/1
on subframe with
fitting tool
3046
.
Secure
engine support
T50015
and preload it slightly.
Remove securing bolts for gearbox mounting
arrows
.
Place
engine and gearbox jack
V.A.G 1383 A
or
engine and gearbox jack
VAS 6931
under gearbox carrier.
Remove securing bolts for gearbox carrier
1
.
Lower gearbox carrier with
engine and gearbox jack
and remove.
Note
Bolts 4 and 5 have already been removed during removal of starter.
Unscrew engine/gearbox securing bolts
1 through 10
except for one securing bolt.
Position
engine and gearbox jack
with a soft foam surface
arrow
under gearbox
1
and also secure gearbox using a tensioning strap.
Remove last engine/gearbox connecting bolt.
Note
Only remove the gearbox with the help of a second mechanic.
Press gearbox off engine (dowel sleeves) and pull out to rear.
Lower gearbox
1
carefully with
engine and gearbox jack
.
Use
support bridge
30 - 211 A
to secure torque converter in gearbox and prevent it falling out.