Removing gearbox with flange shafts; Touran 1.4 l - 103, 110 and 125 kW petrol engine (and 110 kW Eco-Fuel) — 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.
• 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. Follow the instructions for different vehicles .
2. Raise vehicle. All 4 supports of lifting platform must be at same height.
3. Move selector lever to position »P«.
4. Remove front left wheel.
5. Remove engine cover panel.

6. Remove complete air filter housing 24Removing and installing air filter.
7. Remove battery and (battery tray)27Battery; Removing and installing battery.
8. Remove starter Electrical system27Removing and installing starter.
9. Remove selector lever cable from ball head, remove securing clip.
10. Therefore, when installing, always use a »new« securing clip.
11. Now remove all upper connecting bolts between engine and gearbox.
12. Release mechatronic unit connector by pulling and pull off connector.
13. Remove noise insulation 50Assembly overview - noise insulation.
14. Remove front left wheel housing liner.
15. Remove all retainers and brackets from front of gearbox.
16. If fitted, remove the heat shield over the right-hand drive shaft. Tightening torque 40Repairing drive shafts
17. Unbolt front left vehicle level sender G78 from suspension link.
18. Remove left coupling rod from suspension link and lay to side.
19. Unbolt left suspension link from suspension strut.
20. Unbolt both drive shafts from gearbox and carefully lay to side.
21. Swing left drive shaft into wheel housing onto longitudinal member. This will keep the shaft out of the way during further work.
22. Remove right flange shaft of gearbox using socket T10107 A.
23. Screw 2 bolts into flange and counterhold flange shaft with a lever in order to remove and install flange shaft.
24. Remove flange shaft with compression spring.
25. Close opening in drive shaft using a suitable plug.
26. To install flange shaft, if necessary press against gearbox with a lever and screw in bolt.
27. Disconnect front exhaust system if lower engine/gearbox bolts cannot be removed 26Removing and installing parts of exhaust system.
28. Remove pendulum support.
29. If there are hose and cable connections or retainers in area of support eyes for support bracket10-222A, remove these now.
30. Remove filler pieces from upper edges of both wings.
31. For vehicles with large headlights with round profile, use adapter10 - 222 A /26.
32. Headlights .
33. For vehicles with small headlights, use adapter10 - 222 A /22.
34. Headlights .
35. For vehicles with large headlights without round profile, use adapter10 - 222 A /30.
36. Headlights .
37. Then lower engine and gearbox slightly using spindles of support bracket10 - 222 A so that bracket can be removed.
38. If charge air line is present, remove it.
39. Remove connecting bolt
40. Set up gearbox support3282 with adjustment plate3282/59.
41. Move engine and gearbox jackV.A.G 1383 A under gearbox and support gearbox. Do not raise.
42. Position plate of pin under gearbox housing, not under mechatronic unit.
43. Screw a pin into »rear« hole for pendulum support.
44. Remove remaining engine/gearbox connecting bolts.
45. Press gearbox off engine, »observing selector lever cable« and lower gearbox.

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