Removing gearbox, vehicles up to model year 2010 — VW

Removing gearbox, vehicles up to model year 2010
Special tools and workshop equipment required
Support bracket
10 - 222 A
Adapter
10 - 222 A /22
for vehicles to model year 2010
Adapter
10 - 222 A /30
for vehicles from model year 2011
Hook
10 - 222 A/2
Adapter
10 - 222 A /3
Gearbox support
3282
Adapter
10 -222 A /16
Hose clamps to 25 mm
3094
Support elements
for gearbox (determine when setting
adjustment plate
on
gearbox support
)
Pin
3282/29
Adjustment plate
3282/42 A
Socket
T10061
Insert tool, 18 mm
T10179
Spring-type clip pliers
VAS 5024 A
tensioning straps
T10038
Note
Renew all self-locking nuts and bolts.
Renew all bolts which must be tightened further to a torque angle.
All cable ties which were opened or cut during removal must be renewed at the same points when component is installed.
All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.
Brief description
The gearbox is removed downwards separately. From above:
remove battery, air filter, selector lever cable and starter,
clamp off coolant hoses and, before removing left assembly mounting, support engine and gearbox.
From below:
remove left drive shaft,
disconnect right drive shaft and suspend from body,
detach exhaust system and remove wheel housing liner,
remove pendulum support.
Removing
Raise vehicle. All 4 supports of lifting platform must be at same height.
Move selector lever to position
»P«
.
Remove engine cover panel
Rep. gr.
10
Engine cover panel; Removing and installing engine cover panel
.
Remove air filter housing
Rep. gr.
23
Air filter; Removing and installing air filter housing
.
Remove battery and battery tray
Rep. gr.
27
Battery; Removing and installing battery
.
Unscrew nut
arrow
and tie up earth cable to one side.
Disconnect
wiring harness
coming
»from below«
from subframe.
Disconnect wire
1
from electronics box.
Disconnect earth cable
2
.
Separate connector
3
.
This wiring harness will later be removed together with the subframe. This will save time by avoiding work on the steering and heat shield.
Note
On a warm engine, the cooling system is under high pressure.
Before pulling off the coolant hoses, cover the cap on the coolant expansion tank with a cloth and open carefully.
Clamp off coolant hoses on gear oil cooler using
hose clamps up to 25 mm
3094
.
Release/loosen spring-type clip using
spring-type clip pliers
VAS 5024 A
. Pull coolant hoses off gear oil cooler.
Place coolant hoses to one side.
Pull vacuum hose
2
off suction hose
1
, and lay it to one side. Unclip bracket.
Unscrew bolt
4
fully (cannot be lost).
Swing intake union to the right and remove with suction hose
1
.
Release mechatronic unit connector
arrow
by turning it towards left, and pull off connector.
Remove starter, and tie up wiring harness on radiator
Electrical system
Rep. gr.
27
Starter; Removing and installing starter
.
Remove top engine/gearbox connecting bolts
1
and
10
with
insert tool 18 mm
T10179
.
A bolt
3
is located in the starter motor hole. Use
socket
T10061
for these bolts.
These tools are appropriate for this.
Remove connecting hose
arrow
.
Remove bolts
arrows
of charge air pipe.
Take out charge air pipe.
Remove air hose by loosening hose clamps
1
and
2
.
If there are hose and cable connections in area of engine support eye for
support bracket
10 - 222 A
, remove these now.
Remove filler pieces from upper edge of left and right wings.
Set up
support bracket
10 - 222 A
together with
adapters
10 - 222 A /22
,
adapter
10 - 222 A /3
and
adapter
10 - 222 A /16
behind gas strut for bonnet.
Attach
hook
10 - 222 A /10
to front right of engine.
Connect
hook
10 - 222 A /2
.
Then connect
hook
10 - 222 A /2
into
adapter
10 - 222 A /16
.
Take up weight of engine/gearbox assembly on spindles.
Raise vehicle.
Remove noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview – noise insulation
.
Remove front left wheel housing liner
General body repairs, exterior
Rep. gr.
66
Wheel housing liners; Assembly overview – front wheel housing liner
.
Move clear and tie up connector and wires on retaining plate.
Unscrew nuts
arrows
and remove bracket.
Pull back securing lever
1
onto stop
Push down securing lever
2
and pull off connector
Remove exhaust system bracket from subframe
arrows
.
Separate exhaust system at double clamp
arrows
.
The flexible joint of the front exhaust pipe must not be bent more than 10° – danger of damage.
If the catalyst is to be reused, always attach a
transport guard for decoupling element
T10404
arrow
to the decoupling element in the front exhaust pipe.
First unscrew bolt
1
from pendulum support.
Unscrew bolts
2
and
3
for pendulum support.
Disconnect left drive shaft from gearbox flange shaft.
Place inner drive shaft joint
1
over flange shaft of gearbox. The surface protection of the shafts must not be damaged.
Unscrew bottom nut
2
of left coupling rod.
Caution
Damage to vehicle
The wheel bearing can be damaged by the vehicle's own weight when the bolt is unscrewed.
Do not loosen the bolt if the vehicle is standing on its wheels.
Press brake pedal to remove bolt for drive shaft
arrow
(second mechanic required).
Note
Remove drive shaft later on due to lack of available space.
Removing right drive shaft from gearbox flange shaft
A
Remove bolt
arrow
.
Remove cover plate
A
for flywheel and take out in
direction of arrow
.
Pull off securing clip
3
of selector lever cable in
direction of arrow
.
Unscrew bolts
1
of cable support bracket
2
and place selector lever cable to one side.
Unscrew bolts
2
of left assembly mounting from gearbox bracket
A
.
Unscrew bolts
1
for gearbox bracket
A
.
Note
Only loosen bolts of engine mounting. Do not remove them or the engine will not have any support.
Unscrew bolts
A
of right assembly mounting by about 20 ... 30 mm.
Pull off vacuum line from brake servo.
Lower engine/gearbox assembly to dimension
a
.
Dimension
a
between lower side of left assembly mounting
1
and gearbox bracket
2
= approx 50 mm
Caution
Damage to vehicle
Damage to components may occur.
When lowering or moving the engine/gearbox assembly, ensure that no cables, hoses, etc. become damaged.
Note
Lower threaded spindle of
adapter
10 - 222 A /16
using winged nut, but not more than until spindle is flush with nut.
Make sure there is always sufficient clearance from other components.
Remove gearbox bracket in direction of
arrow
.
Pull engine and gearbox assembly forwards as far as possible in direction of normal travel.
Unscrew engine/gearbox bolts
5
,
6
,
7
and
8
.
Turn steering fully onto left lock.
Pull out left drive shaft from wheel hub. Remove left drive shaft.
Gearbox support
3282
is aligned with
adjustment plate
3282/42A
for removal of gearbox 02E.
Insert
gearbox support
3282
in
engine and gearbox jack
V.A.G 1383 A
.
Align arms of
gearbox support
3282
according to holes in
adjustment plate
3282/42A
.
Fit
support elements
into
adjustment plate
3282/42A
as illustrated.
Position
engine and gearbox jack
V.A.G 1383 A
under vehicle. Arrow on
adjustment plate
3282/42A
points in direction of travel.
Align arms of
gearbox support
3282
in relation to gearbox, as shown in figure.
Note
The
adjustment plates
3282/48
and
3282/52
are part of the
gearbox support
3282
.
Unscrew last remaining engine/gearbox connecting bolt in area of right flange shaft.
Press gearbox away from engine, off dowel sleeves.
When lowering gearbox, change position of gearbox using spindles of
gearbox support
3282
.
Carefully drain gear oil.
Note
Make sure that the right flange shaft is guided past the flywheel when the gearbox is being removed.
Check needle roller bearing
arrow
in crankshaft. If it is damaged or tarnished blue, it must be renewed
Rep. gr.
13
Crankshaft; Renewing needle bearing in crankshaft
.