Removing gearbox, Sharan 2011 ► with 2.0 l diesel engine — VW

🧭 Before you start

Fits: VW Sharan II / SEAT Alhambra (7N, 2010–)

• Special tools named: T10107

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• Raise vehicle. All 4 supports of lifting platform must be at same height.
• After loosening centre bolt, do not lower vehicle to ground again.
• Remove cable with great care from cable support bracket on gearbox. Do not bend cable.
• Before removing flange shaft, check oil seal for leaks. If oil seal is leaking, it must be renewed before flange shaft is installed.
• Screw 2 bolts into flange and counterhold flange shaft with a lever in order to remove and install flange shaft.

📋 Procedure

1. Raise vehicle. All 4 supports of lifting platform must be at same height.
2. Move selector lever to position »P« position. [Note: After loosening centre bolt, do not lower vehicle to ground again.]
3. Depress brake pedal to remove bolt for left drive shaft (arrow). A second mechanic is required.
4. Remove cover from engine.
5. Then pull off grommet (arrow) so that it is not damaged when supporting engine.

6. Therefore remove plenum chamber cover: 50Plenum chamber cover; and remove radiator grille 66Radiator grille.
7. Remove complete air filter housing 24Removing and installing air filter.
8. Remove battery and battery tray 27Battery; Removing and installing battery.
9. Release mechatronic unit connector (1) by turning and pull off connector.
10. Remove starter (A)Electrical system27Removing and installing starter.
11. Remove selector lever cable from gearbox.
12. Remove cable with great care from cable support bracket on gearbox. Do not bend cable.
13. Clamp off coolant hoses using hose clamps to 40 mm3093 or hose clamps to 25 mm3094 and remove.
14. Remove charge air line 21Removing and installing parts of charge air cooling.
15. Remove upper engine/gearbox connecting bolts.
16. Remove noise insulation and front left wheel housing liner General body repairs, exterior66Removing and installing wheel housing liner; Front wheel housing liner.
17. Remove left drive shaft 40.
18. If present, remove heat shield above right drive shaft. Tightening torque 40Repairing drive shafts
19. Unbolt right drive shaft from gearbox and secure to suspension strut using securing straps T1003840.
20. Remove pendulum support. First remove bolt (1), followed by bolts (2) and (3)40.
21. Unbolt wiring retainer from front of »black« gearbox cover (arrows) (2 nuts M6).
22. Support engine and gearbox.
23. Set up support bracket10-222 A behind bonnet support:
24. First put on adapter10-222A/8(A) next to bolts (arrow) on left side.
25. Then set up support bracket10-222A behind bonnet support. Also set up right adapter10-222A/8 next to bolts (arrow).
26. Attach lugs2024 A / 1 in engine support eyes.
27. Connect lugs2024 A / 1 to spindle10 - 222 A /10 using shackle10 - 222 A /12.
28. Set up adapter T40093/3 with adapter T40093/3-5 (notch (A)) on sheet metal fold of bumper carrier.
29. Push one spindle onto square tube T40091/1.
30. Assemble square tube T40091/1 with adapter T40093/3 and support bracket10-222A.
31. Then attach spindle in front engine support eye.
32. Take up weight of engine/gearbox assembly on spindle.
33. Remove all bolts (1) and (2) for bracket (A).
34. Then lower engine/gearbox slightly using spindles of support bracket10 - 222 A and remove bracket. [Note: Before removing flange shaft, check oil seal for leaks. If oil seal is leaking, it must be renewed before flange shaft is installed.]
35. Remove right flange shaft of gearbox using socket T10107 A.
36. Screw 2 bolts into flange and counterhold flange shaft with a lever in order to remove and install flange shaft.
37. Pull out flange shaft with compression spring.
38. Close opening in drive shaft using a suitable plug.
39. When flange shaft is reinstalled, compression spring prevents bolt engaging in thread. If necessary press flange shaft against gearbox with a lever and screw in bolt.
40. Set up gearbox support3282 with adjustment plate3282/42 A.
41. Move engine and gearbox jackV.A.G 1383 A under gearbox and support gearbox. Do not raise.
42. Remove remaining engine/gearbox connecting bolts.
43. Press gearbox off engine, »observing selector lever cable« and lower gearbox.

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