Removing gearbox - vehicles with 3.6 l - 206 kW engine: VW Passat B6

🧭 Before you start

Fits: VW Passat B6 (3C, 2005–2010)

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• The subframe is not to be removed.
• Raise vehicle. All 4 supports of lifting platform must be at same height.
• After loosening bolt, do not lower vehicle to ground again.
• So that the propshaft can be turned later in order to loosen it:
• Mark position of propshaft with flexible coupling relative to output shaft of bevel box.

📋 Procedure

1. Before removing, print diagnosis log. Return removed gearbox together with log in the customary manner. [Note: The subframe is not to be removed.]
2. Before removal, print out a diagnosis log for this vehicle. Before returning the gearbox in the usual manner, secure the log to the gearbox so that it cannot be lost during transport.
3. Raise vehicle. All 4 supports of lifting platform must be at same height.
4. Turn steering to straight-ahead position.
5. Pull out ignition key and engage steering wheel lock.

6. Move selector lever to position »P« position.
7. Loosen both drive shafts. [Note: After loosening bolt, do not lower vehicle to ground again.]
8. Remove both front wheels. [Note: So that the propshaft can be turned later in order to loosen it:]
9. Move selector lever to »N« position.
10. Pull out ignition key and engage steering wheel lock.
11. Disconnect battery 27Battery; Disconnecting and connecting battery.
12. Remove complete air filter housing 24Removing and installing air filter and bracket below.
13. Separate all electrical connections to gearbox and starter which are »better accessible from above«.
14. Release selector lever cable from gearbox by hand (1) and pull out of cable support bracket (2).
15. Then lever cable off ball head (2).
16. ⚠ Hot steam may escape when expansion tank is opened. Wear protective goggles and clothing to avoid eye injuries and scalding. Cover cap with a cloth and carefully open. — Open cap on expansion tank.
17. Clamp off coolant hoses using hose clamps to 25 mm3094 and remove.
18. Unbolt coolant lines (1) and (2) from engine and unhook wiring harness.
19. Now remove all upper connecting bolts between gearbox and engine.
20. Remove noise insulation tray and »lower« part of front left wheel housing liner General body repairs, exterior66Removing and installing wheel housing liners; Front wheel housing liners.
21. First unscrew (nuts) from lower suspension links on both sides.
22. Pull connector off front left vehicle level sender G78.
23. Press both drive shafts off gearbox and remove.
24. Remove pendulum support, first (A) and then (B).
25. Remove heat shield above right drive shaft.
26. Mark position of propshaft with flexible coupling relative to output shaft of bevel box.
27. Unbolt propshaft (arrows) and pull off from bevel box.
28. Counterhold at rear final drive when loosening or tightening propshaft. [Note: To loosen »next« bolt, turn propshaft further by turning rear wheels at same time.]
29. Therefore, clamp assembly tool T10071 tight with a cloth. This »protects« the ring.
30. Remove bracket (A) between engine block and bevel box.
31. Unbolt bevel box at top from gearbox (arrows).
32. Unbolt bevel box at bottom from gearbox (arrows).
33. Pull connector (1) off oil level and oil temperature sender G266.
34. Press engine and gearbox forwards by hand and fix in this position with an appropriate piece of wood (A).
35. Carefully press bevel box off gearbox and remove downwards.
36. Pull out plug.
37. Through this (opening), remove six torque converter nuts with insertV/175. Counterhold with screwdriver on starter ring gear.
38. Remove all but one »easily accessible« connecting bolt between gearbox and engine.
39. Separate the two electrical connections to gearbox which are easily accessible »from below«.
40. Clamp off ATF lines (2) with hose clamps to Ø 25 mm3094.
41. Remove bolt (1) and pull ATF lines (2) off gearbox.
42. Seal off gearbox and ATF lines with clean plugs.
43. Remove intake hose from throttle valve housing and lay to side in order to create sufficient »clearance« for the »rear« spindle of the support bracket.
44. Set up support device10 - 222 A.
45. Suspend and support engine and gearbox. Do not raise.
46. Remove gearbox/bracket bolts (1).
47. Unbolt bracket (2) from gearbox.
48. Then lower engine and gearbox using the spindles of the support bracket10 - 222 A about 6 turns.
49. Remove bracket.
50. Set up gearbox support3282 with adjustment plate3282/56.
51. Move engine and gearbox jackV.A.G 1383 A under gearbox and support gearbox. Do not raise.
52. Now remove »last« engine/gearbox securing bolt.
53. Carefully lower gearbox, ensuring »clearance« to other components.
54. For purposes of analysis, attach diagnosis log of this gearbox securely to gearbox when it is ready for shipping.

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