Removing gearbox, Crafter 4MOTION with Achleitner four-wheel drive — VW

Removing gearbox, Crafter 4MOTION with Achleitner four-wheel drive
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Engine and gearbox jack
V.A.G 1383 A
Tensioning strap
T10038
Engine support
T50015
Removing
Note
Cable retainers and clips which were removed or loosened must be reinstalled in the same positions.
Disconnect battery
Electrical system
Rep. gr.
27
Battery; Disconnecting and connecting battery
.
Remove air filter
Rep. gr.
23
Air filter; Removing and installing air filter
.
Raise vehicle
Maintenance
Booklet
10.2
.
If fitted, remove noise insulation at front, centre and rear
General body repairs, exterior
Rep. gr.
66
Noise insulation; Removing and installing noise insulation
.
Secure vehicle with
tensioning belts
T10038
to lifting platform on both sides.
For this, guide
tensioning strap
T10038
through hole in body
arrow
and around support arm of lifting platform. Then tension
tensioning strap
T10038
.
WARNING
If the vehicle is not strapped down, it may slip off the lifting platform.
Remove transfer box
Rep. gr.
34
Transfer box, Crafter 4MOTION with Achleitner four-wheel drive
.
Removing gearbox carrier
Chapter
.
Note
When removing gearbox carrier, transfer box is secured with
engine and gearbox jack
V.A.G 1383 A
and manual gearbox is secured with
retaining tool
VW 785/1 B
If gearbox is to be removed, remove
retaining tool
VW 785/1 B
after successfully removing carrier. For this,
engine and gearbox jack
V.A.G 1383 A
must be placed under manual gearbox for removal of gearbox.
Place
engine and gearbox jack
V.A.G 1383 A
under gearbox with a wooden block
1
.
Remove locking bar
3
, slackening securing bolt
4
to do so.
Pull selector cables
1 and 2
off ball heads of selector mechanism
arrows
.
Detach selector cables from gearbox.
If present, remove
tachograph sender
G75
arrow
.
Note
Lead seal of
tachograph sender
G75
is only allowed to be attached by authorised specialist workshops
Electrical system
Rep. gr.
90
.
Pull connector off
gearbox neutral position switch
F365
arrow
, if fitted.
Using a screwdriver, press securing clip
1
out of hydraulic line for clutch slave cylinder with release bearing.
Pull off hydraulic line.
Note
Seal detached hydraulic line, e.g. using dust cap of rear brake caliper.
Caution
It is not permitted to support the engine between the sump and the steering rack.
This manner of support can lead to damage to the steering rack.
As a consequence, hydraulic fluid leaks may develop in the steering rack, leading to the failure of power steering.
Lower
engine and gearbox jack
V.A.G 1383 A
.
Unscrew securing bolts for starter
6
(engine end) and
7
(gearbox end).
Note
Starter remains attached to engine.
Unscrew engine/gearbox connecting bolts
1...4
. Do not yet unscrew the last connecting bolt
5
.
Note
Under connecting bolts
1
and
3
, there are retainers for lines. Tie-up retainers to one side to keep them out of the way during removal and installation of the gearbox.
Secure gearbox on
engine and gearbox jack
V.A.G 1383 A
using
tensioning belt
T10038
.
Unscrew the last engine/gearbox connecting bolt
5
at engine end.
Carefully push gearbox off engine.
Lower gearbox.
Note
When installing an exchange gearbox, the cable support bracket may have to be transferred from the old gearbox.