Removing gearbox, Passat 2006 ► with 2.0 l diesel engine — VW

🧭 Before you start

Fits: VW Passat B6 (3C, 2005–2010)

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• Raise vehicle. All 4 supports of lifting platform must be at same height.
• Support engine and gearbox with support bracket10 - 222 A, adapter10 - 222 A /18, hooks10 - 222 A /10 and adapter10 - 222 A /8. Do not raise.
• Move engine and gearbox jackV.A.G 1383 A under gearbox and support gearbox. Do not raise.
• Observe connecting lines, hoses and radiator when moving engine/gearbox assembly.

📋 Procedure

1. Raise vehicle. All 4 supports of lifting platform must be at same height.
2. Move selector lever to position »P« position.
3. Remove complete air filter housing 23Removing and installing air filter.
4. Remove intake hose from turbocharger so that rear eye is accessible for »hanging« engine.
5. Remove battery and (battery box)27Battery; Removing and installing battery.

6. Remove upper starter motor bolt.
7. Remove selector lever cable from gearbox.
8. Clamp off coolant hoses using hose clamps to 40 mm3093 or hose clamps to 25 mm3094 and remove.
9. Release mechatronic unit connector by turning and pull off connector.
10. Unbolt wiring retainer from front of »black« gearbox cover (2 nuts M6).
11. Now remove all upper connecting bolts between gearbox and engine.
12. Remove noise insulation and lower part of front left wheel housing liner General body repairs, exterior66Removing and installing wheel housing liners; Front wheel housing liners.
13. Remove connecting hose between charge air cooler and charge air pipe 21Removing and installing parts of charge air cooling.
14. Remove radiator fan support.
15. Pull connector (1) off oil level and oil temperature sender G266.
16. Remove exhaust system bracket from subframe (arrows).
17. Separate exhaust system at double clamp (arrows).
18. Tie up front exhaust pipe or put down tunnel cross member.
19. Remove left coupling rod from suspension link and lay to side.
20. Unscrew left transverse link from suspension strut.
21. Unbolt both drive shafts from gearbox and carefully lay to side.
22. Swing left drive shaft into wheel housing onto longitudinal member. This will keep the shaft out of the way during further work.
23. If fitted, remove the heat shield over the right-hand drive shaft. Tightening torque 40Repairing drive shafts
24. Unbolt front left vehicle level sender G78 from suspension link.
25. Remove pendulum support, bolt (1), (2) and bolt (3).
26. Unbolt right securing bolt for heat shield (1) from subframe.
27. Screw bracket T10346 tight using a suitable bolt (2).
28. Attach engine support3300 A on bracket T10346.
29. If there are hose or wiring connections near the engine lifting eyes, remove them now.
30. Support engine and gearbox with support bracket10 - 222 A, adapter10 - 222 A /18, hooks10 - 222 A /10 and adapter10 - 222 A /8. Do not raise.
31. Remove all bolts (1) and (2) for bracket (A).
32. Then lower engine and gearbox slightly using spindles of support bracket10 - 222 A so that bracket can be removed.
33. Remove lower starter bolt and remove starter.
34. Remove bolt in starter hole.
35. A small cover plate is located above the right drive shaft flange on the intermediate plate for engine and gearbox. Remove this cover plate (A).
36. Lower engine and gearbox until there is sufficient »clearance« between upper edge of gearbox and left longitudinal member.
37. Set up gearbox support3282 with adjustment plate3282/42 A.
38. Move engine and gearbox jackV.A.G 1383 A under gearbox and support gearbox. Do not raise.
39. Remove remaining engine/gearbox connecting bolts.
40. Carefully press engine and gearbox forwards. [Note: Observe connecting lines, hoses and radiator when moving engine/gearbox assembly.]
41. Press gearbox off engine, »observing selector lever cable« and lower gearbox.

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