Removing gearbox; Touran 1.6 l - 77 kW - TDI engine — VW

🧭 Before you start

Fits: VW Touran I (1T, 2003–2015)

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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.
• Therefore, when installing, always use a »new« securing clip.
• Screw 2 bolts into flange and counterhold flange shaft with a lever in order to remove and install flange shaft.
• Move engine and gearbox jackV.A.G 1383 A under gearbox and support gearbox. Do not raise.

📋 Procedure

1. Raise vehicle. All 4 supports of lifting platform must be at same height.
2. Move selector lever to position »P«.
3. Step on the brake pedal while a 2nd mechanic loosens the left drive shaft bolt (arrow). [Note: After loosening centre bolt, do not lower vehicle to ground again.]
4. Remove engine cover panel.
5. Remove complete air filter housing 24Removing and installing air filter.

6. Remove battery with battery tray 27Battery; Removing and installing battery.
7. Remove starter Electrical system 27. Removing and installing starter.
8. Remove selector lever cable from ball head, remove securing clip.
9. Therefore, when installing, always use a »new« securing clip.
10. Release mechatronic unit connector by pulling and pull off connector.
11. Remove noise insulation 50Assembly overview - noise insulation.
12. Unbolt front left vehicle level sender G78 from suspension link.
13. Remove left coupling rod from suspension link and lay to side.
14. Remove left drive shaft Running gear, axles, steering 40. Removing and installing drive shafts.
15. If present, remove heat shield above right drive shaft. Tightening torque 40Repairing drive shafts
16. Unbolt right drive shaft from gearbox.
17. Secure right drive shaft to suspension strut with tensioning belt T10038.
18. Remove right flange shaft of gearbox using socket T10107 A.
19. Screw 2 bolts into flange and counterhold flange shaft with a lever in order to remove and install flange shaft.
20. Remove flange shaft with compression spring.
21. Close opening in drive shaft using a suitable plug.
22. To install flange shaft, if necessary press against gearbox with a lever and screw in bolt.
23. Remove all retainers and brackets from front of gearbox.
24. Remove pendulum support.
25. If there are hose and cable connections or retainers in area of support eyes for support bracket10-222A, remove these now.
26. Support engine and gearbox.
27. Preload engine and gearbox using spindles hooks10 - 222 A /10 and adapter10 - 222 A /16 by about 5 rotations each.
28. Then lower engine and gearbox by about 5 rotations using spindle hooks10 - 222 A /10 and remove bracket.
29. Then raise engine and gearbox again using spindle hook10 - 222 A /10 by these 5 rotations.
30. Remove charge air line. 21Turbocharging/supercharging
31. Remove upper engine/gearbox connecting bolts.
32. Set up gearbox support 3282 with adjustment plate 3282/59.
33. Move engine and gearbox jack V.A.G 1383 A under gearbox and support gearbox. Do not raise.
34. Position plate of pin under gearbox housing, not under mechatronic unit.
35. Screw a pin into »rear« hole for pendulum support.
36. Remove remaining engine/gearbox connecting bolts.
37. Press gearbox off engine, »observing selector lever cable« and lower gearbox.
38. Note clearance of gearbox from subframe when lowering. Tilt gearbox using spindle of gearbox support 3282 and lower slowly.

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