Removal and Installation of Automatic Transmission

GENERAL INFORMATION

CAUTION

Operations and instructions common to both the manual transmission and the automatic transmission are described in the subsection Removal and Installation of Manual Transmission for Turbocharged Diesel Engines (TDI).

This subsection describes only the differences related to the automatic transmission.

PROCEDURE

1. Support the engine by the cylinder head using a hoist.

2. Disconnect the plug connector at the automatic transmission and disconnect the cable guide.

1 – solenoid valve sensor (10-pin) 2 – vehicle speed sensor 3 – multifunction switch 4 – transmission speed sensor

3. Pry the shift linkage rod (1) off lever (4) with a screwdriver. Remove retaining clip (3) at the support. Disconnect the shift linkage rod from the transmission and move it aside.

CAUTION

Do not loosen bolt (2).

4. Unscrew the mounting bolts and remove the power steering pump pressure line bracket.

5. Clamp the ATF cooler hoses, for example with tool VW-3094 or HAZET-4590.

Loosen the clamps and remove the hoses.

CAUTION

Wipe up leaked oil with a rag.

6. Unscrew the mounting bolts and remove the cover plate (arrows in the illustration).

7. Remove the plug from the torque converter cover opening. Unscrew the 3 nuts and disconnect the torque converter from the clutch driven plate (arrow in the accompanying illustration). Turn the engine clockwise using a socket on the crankshaft pulley so that the nuts are accessible through the opening.

CAUTION

The torque converter is located between the engine and the transmission and is a fluid coupling.

8. Remove the automatic transmission in the same way as the manual transmission (see Removal and Installation of Manual Transmission).

CAUTION

When removing the automatic transmission from the engine, push the torque converter off the drive plate. Secure the torque converter in the transmission so it does not fall out, by installing a clamping device on the transmission housing and tightening it. If such a device is not used, make sure the torque converter does not slide out of the transmission when removing it.

INSTALLATION

9. Before installing the automatic transmission, measure the distance between the transmission housing flange and the lower support surface at the threaded stud. It must be approximately 22 mm. If the measured distance is 10 mm, the torque converter is installed incorrectly. In this case, carefully turn the torque converter so that it slides down.

CAUTION

If the torque converter is installed incorrectly, the drive plate will be damaged when the transmission is installed.

10. Install in the reverse order of removal. Additionally, observe the following:

CAUTION

following.

11. Use only original nuts to secure the torque converter. Tighten the torque converter to the clutch driven plate to a torque of 60 N·m.

12. Replace the transmission mount bolts. Tighten the bolts to the torques shown in the illustration.

13. Adjust the shift linkage.

14. Check the ATF level in the final drive and in the transmission.