Removing gearbox, four-wheel drive — VW

Removing gearbox, four-wheel drive
Special tools and workshop equipment required
Support bracket
10 - 222 A
Hook
10 - 222 A /2
Adapter
10 - 222 A /3
Shackle
10 - 222 A /12
Adapter
10 - 222 A /16
Adapter
10 - 222 A /23
Hose clamps to 25 mm
3094
Extension
2024 A/1
Lifting tackle
3033
Gearbox support
3282
Adjustment plate
3282/51
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Engine and gearbox jack
V.A.G 1383 A
Grease
Electronic Parts Catalogue
Grease
Electronic Parts Catalogue
Bolt M10 x 20
First check whether a coded radio is installed. If necessary, identify anti-theft coding.
Remove engine compartment cover.
Remove outer lock carrier covers above headlights.
With ignition switched off, disconnect battery (repair group 27: Disconnecting and connecting battery).
Remove plenum chamber cover (repair group 66: Mouldings and trims; Removing and installing plenum chamber cover). (repair group 26: Cleansing exhaust emission).
Unbolt coolant expansion tank (1) and place to side. Do not open cooling system.
Unbolt connecting hose with intake connecting pipe (2) from intake manifold and remove it from charge air cooler (repair group 21: Charge air system).
Pull off connector on retainer for vacuum reservoir (3).
Remove bracket for vacuum reservoir (3) from plenum chamber.
Remove any noise insulation (4) from front plenum chamber.
Remove gear selector cable (A) from gearbox selector lever and gate selector cable (B) from relay lever by pressing securing clips arrow 1 and arrow 2.
Remove cable support bracket (C) from gearbox by operating catch in direction of arrow 3.
Then remove left and right plenum chamber bulkhead panels from plenum chamber (repair group 50: Assembly overview - plenum chamber bulkhead).
Remove deflector caps for suspension struts.
Place adapter
10 - 222 A /23 at rear on suspension strut arrow A and at front on lock carrier arrow B.
If there are hose and cable connections in area of engine support eye for support bracket
10 - 222 A
, remove these now.
For vehicles with engine codes BNY and BPC, the exhaust gas recirculation valve
N18 must be removed.
Secure support bracket
10 - 222 A in conjunction with adapter
10 - 222 A /3 and adapter
10 - 222 A /16 to adapter
10 - 222 A /23.
Hook shackle
10 - 222 A /12 into retaining eye on front of engine and then insert spindle
10 - 222 A /11 in shackle.
Attach hook
10 - 222 A /2 in rear lifting eye on engine.
Slightly preload engine/gearbox assembly using spindle
10 - 222 A /11 and adapter
10 - 222 A /16.
Loosen wheel bolts on front left and front right.
Raise vehicle.
Remove front wheels.
Remove noise insulation below engine and gearbox.
Remove engine noise insulation, if present, from sump.
If fitted, remove noise insulation for left and right drive shafts from wheel housing.
Remove exhaust system bracket from subframe, separate exhaust system at double clamp and tie up on body.
Vehicles with 6-cylinder petrol engine
Remove heat shield (arrow) from bevel box.
Continuation for all vehicles
Check whether a mark (coloured spot) is present on constant velocity joint of front propshaft tube and on output flange of bevel box.
If no such mark is present, mark position of output flange of bevel box arrow A relative to propshaft constant velocity joint arrow B with coloured mark.
Remove front propshaft tube (repair group 39: Final drive, rear differential).
Remove subframe. Note attachment of subframe (repair group 40: Assembly overview - subframe; Removing and installing subframe).
Remove right track rod from wheel bearing housing and tie up together with steering rack on body (repair group 48: Assembly overview - steering rack; Removing and installing steering rack).
If fitted, remove noise insulation (A) from gearbox (arrows).
Press left drive shaft off stub shaft on gearbox and tie it up (repair group 40: Drive shafts; Removing and installing drive shaft).
Press left right shaft off stub shaft on gearbox and tie it up (repair group 40: Drive shafts; Removing and installing drive shaft).
Note
Pendulum support bolts always must be renewed.
Remove gearbox carrier (A) from rear torque reaction support (B) and from bevel box (bolts (1) and (2)). (repair group 10: Assembly mountings).
Unscrew engine/gearbox connecting bolt arrow A behind bevel box (1).
Note
Do not yet loosen engine/gearbox connecting bolt arrow B.
Unbolt wiring harness retainer from starter.
Remove earth strap (1) from lower starter bolt.
Pull off connector for reversing light (2).
Remove connector and wire from starter.
Remove starter (3) (repair group 27: Removing and installing) starter.
Clamp off hose of pipe/hose assembly (A) to slave cylinder using hose clamp up to 25 mm
3094.
Pull out clip (arrow) for pipe/hose assembly to stop.
Pull pipe/hose assembly with bleeder from slave cylinder.
Caution
Do not depress clutch pedal any longer.
Remove connector from drive for tachograph, if fitted.
Remove bracket (A) for power assisted steering lines from gearbox (arrow).
Position engine and gearbox jack
V.A.G 1383 A with universal support
V.A.G 1359/2 under gearbox and exert slight counter pressure.
Unscrew hexagon bolts (arrows) for left power unit mounting.
Remove
engine and gearbox jack
V.A.G 1383/A with universal support
V.A.G 1359/2 from beneath gearbox.
Using adapter
10-222 A/16 and spindle of support bracket
10-222 A
, lower engine/gearbox approx. 100 mm to dimension a.
Measure dimension a between lower side of left longitudinal member (1) and bolting surface of gearbox mounting (2).
When lowering engine and gearbox, guide front torque reaction support with support mounting past body.
Ensure clearance between engine and right longitudinal member.
The lower coolant pipe (A) may not rest on right longitudinal member (B).
Remove upper (arrows) and lower (A) engine/gearbox connecting bolts.
To remove
“0A5 all-wheel drive” gearbox, set up gearbox support
3282 with adjustment plate
3282/51.
Insert gearbox support
3282 in engine and gearbox jack
V.A.G 1383 A.
Align arms of gearbox support according to holes in adjustment plate.
The symbols on the adjusting plate indicate the supports required. Arrow does not point in direction of travel.
Position engine and gearbox jack
V.A.G 1383/A with gearbox support
3282 under vehicle.
Secure support (arrow) to gearbox with a bolt M10 x 20.
Support bevel box near oil drain plug with support pin of gearbox support
3282.
Remove engine/gearbox connecting bolt (arrow).
Remove last engine/gearbox connecting bolt arrow B in figure N34-10410.
Press gearbox off engine (dowel sleeves) and carefully swing towards left longitudinal member.
Then carefully lower gearbox. When doing this, guide reversing light switch (arrow) past left longitudinal member.
Guide output flange of bevel box past steering rack when lowering.