Removing gearbox, vehicles with 1.6 l, 81 kW engine — VW

🧭 Before you start

Fits: platform codes AU1, BX5

• Special tools named: T40091/1, V.A.G 1383

Don't miss

• Observe Repair instructions.All cable ties which were opened or cut during removal must be renewed at the same locations.
• After loosening bolt, do not lower vehicle to ground again.
• Raise vehicle slightly. All 4 supports of lifting platform must be at same height.
• Do not remove securing clip (5).Do not bend or kink selector lever cable.
• If fitted, pull off electrical wiring in front area of web on both longitudinal members (arrow). Do not disconnect pipe/hose system.

📋 Procedure

1. If adapter 10 - 222 A /4 does not yet have hole (marked with (arrow)), hole must now be drilled into adapter. [Note: Observe Repair instructions.All cable ties which were opened or cut during removal must be renewed at the same locations.]
2. With vehicle standing on its wheels, loosen left and right twelve-point bolt (arrow) by no more than 90°, otherwise wheel bearing will be damaged Running gear, axles, steering40Drive shaft; Loosening and tightening threaded connections of drive shaft. [Note: After loosening bolt, do not lower vehicle to ground again.]
3. Raise vehicle slightly. All 4 supports of lifting platform must be at same height.
4. Move selector lever to position »P«.
5. Disconnect battery Electrical system27Battery; Disconnecting and connecting battery.

6. Remove air filter housing 24Air filter; Removing and installing air filter housing.
7. Remove battery and battery tray (1)Electrical system27Battery; Removing and installing battery tray.
8. Using an open-end spanner, for example, lever selector lever cable (1) off gearbox selector lever (3).
9. Pull connector off multifunction switch F125.
10. Detach selector lever cable (1) from clip (3) on retainer (2).
11. Remove cable support bracket (4) from gearbox. To do this, unscrew bolts (arrows). [Note: Do not remove securing clip (5).Do not bend or kink selector lever cable.]
12. Remove starter Electrical system27Starter; Removing and installing starter.
13. Lay lint-free cloths on ATF cooler and gearbox to catch escaping coolant. [Note: Mark coolant hoses to ATF cooler to prevent interchanging during installation.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.]
14. Clamp off coolant hoses using hose clamps, up to 25 mm in diameter3094, and disconnect them from ATF cooler.
15. Seal coolant hoses and connection unions using suitable bungs/plugs from engine bung setVAS 6122.
16. Unscrew upper bolts (arrows) connecting gearbox to engine using double hexagon U/J socket (A).
17. Remove filler pipe for washer fluid reservoir of windscreen washer system Electrical system92Windscreen washer system; Removing and installing washer fluid reservoir.
18. On both sides of vehicle, insert adapters10 - 222 A /29 between upper wheel housing longitudinal member and mounting plate for wing located underneath.
19. Adapter(arrow) is engaged in recess of wing.
20. Adapter(arrow) is engaged in recess of wing.
21. Push adapter10 - 222 A /18 and 2 connecting pieces T40091/3 onto engine support bracket10 - 222 A.
22. Insert T40091/1 into connecting pieces T40091/3.
23. Slide spindle10 - 222 A /11 onto T40091/1.
24. Fit spindle10 - 222 A /11 on adapter10 - 222 A /18 as shown in illustration.
25. Secure support bracket10 - 222 A to adapters10 - 222 A /29.
26. Fit shackle10 - 222 A /12 to engine as shown in illustration.
27. Install adapter T40093/3-6(A) as described below (⇒ next illustration).
28. If fitted, pull off electrical wiring in front area of web on both longitudinal members (arrow). Do not disconnect pipe/hose system.
29. Place adapters T40093/3-6 onto both longitudinal members (the figure shows the right longitudinal member).
30. If necessary, carefully unclip any pipes for air conditioning system in front area. Do not disconnect pipe/hose system Heating, air conditioning87Refrigerant circuit; System overview - refrigerant circuit.
31. Bolt on spindles T40093 /3.
32. Connect spindles T40093 /3 via square tubes T40091/1 to engine support bracket10 - 222 A and fasten the connection (⇒ previous Fig.). [Note: The square tubes T40091/1 must not rest against the windscreen.The adapter10 - 222 A /18 must not rest against the wiper arm.]
33. Then, hook spindles into lifting eye of engine. Use shackles10 - 222 A /12 for this.
34. Take up weight of engine/gearbox assembly and support bracket on spindles.
35. Raise vehicle and remove front wheels.
36. Remove noise insulation General body repairs, exterior66Noise insulation; Assembly overview - noise insulation.
37. Remove lower part of front left wheel housing liner General body repairs, exterior66Wheel housing liner; Assembly overview - front wheel housing liner.
38. Remove left and right drive shafts Running gear, axles, steering40Drive shaft; Removing and installing drive shaft.
39. Now pull connectors (1) and (2) at front off gearbox.
40. Open retainer (2) for coolant hose, and remove coolant hose (3).
41. Unclip wiring harness (arrow).
42. Unscrew bolt (4) from engine, and remove retainer (1).
43. Using insertV/175, remove 3 torque converter nuts (arrow) through opening in intermediate plate.
44. To do this, crank engine at pulley/vibration damper 120° in direction of engine rotation. Repeat this for each nut. [Note: If all 3 nuts are not removed from the torque converter, the torque converter will be pulled out when the gearbox is removed from the engine!]
45. Unscrew bolts (1 … 3), and remove pendulum support.
46. Unscrew bolts (arrows) securing exhaust system bracket to subframe.
47. Remove bolts (2) connecting gearbox mounting to gearbox bracket (A) and bolts (1) connecting gearbox bracket to gearbox.
48. Now, remove gearbox bracket (A). To do this, lower engine and gearbox slightly via spindles of support bracket.
49. Remove lower connecting bolts (5 … 7) between engine and gearbox. [Note: Do not unscrew the rear bolts (8) and (9) securing gearbox to engine yet.]
50. Fit gearbox support3282 onto engine and gearbox jackVAS 6931 or V.A.G 1383 A.
51. Then, screw pin3282/29 into rear hole on gearbox for securing bolt of pendulum support (1).
52. Support gearbox via engine and gearbox support by raising it slightly.
53. Remove remaining engine/gearbox connecting bolts (arrow A) and (arrow B). These bolts can be removed using e.g. socket, multi-point bit XZN 14T10061.
54. Press gearbox off engine while simultaneously pressing torque converter out of drive plate of engine.
55. When lowering gearbox, guide it past subframe. If necessary, readjust gearbox support3282 slightly. [Note: The connectors on the front of the gearbox must not be damaged when the gearbox is removed or installed. If a connector becomes damaged, renew the relevant wiring harness in the gearbox .Pay attention to torque converter. It must be removed together with gearbox. Use wire (A), for example, to prevent torque converter from falling out.Illustration of torque converter and gearbox may differ from actual components.]

Other VW procedures

• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures
• Removing and installing camshaft adjuster (cylinder bank 2) · 1 torque figures
• Replacing the optical fibre conductor between the navigation control unit and the front information control unit and the rear information control unit
• Removing gearbox, Golf Plus 2005 ► with 1.4 l petrol engine
• 6-speed dual clutch gearbox 02E — Removing and installing bevel box, Golf 2004 ► and Passat 2006 ►
• Installing mechatronic unit (gearbox removed) – VW · 2 torque figures