Removing gearbox

Brief description

The gearbox is removed downwards separately.

»From above«

»From below«:

Adapter -10 - 222 A /29-

Engine support basic set -T40091-

Engine support supplement set -T40093-

Not required: Engine support supplementary set -T40093/3-5-

Shock absorber set -T10001-

Removal lever -80 - 200-

Insert tool, 18 mm -T10179-

Check adapter -T40093/3-6- and adjust as necessary → Fig.

or Adapter -T40093/3-6A-

Check adapter -T40093/3-6- and adjust as necessary

• If necessary, cut off the marked area.
• Round off the front edges.
• Protect adapter against corrosion.
• Then, mark adapter -T40093/3-6- with -T40093/3-6A-.

Removing

• Raise vehicle. All 4 supports of lifting platform must be at same height.
• Move selector lever to position »P«.
• Remove air filter housing → Rep. gr.24.
• Remove battery and battery tray → Electrical system; Rep. gr.27.

• Using removal lever -80 - 200-, lever selector lever cable -1- off gearbox selector lever.
• Remove bolts -2-, raise and tie selector lever cable together with support bracket.

Caution Risk of damage to selector lever cable. Do not bend or kink selector lever cable.

• Remove starter → Electrical system; Rep. gr.27.

It is advisable to remove the »lower« bolt first.

Caution Risk of damaging gearbox components beyond repair. Do not under any circumstances touch the contacts in the gearbox connector by hand. Electrostatic discharge can seriously damage the control unit and mechatronic unit.

• Touch earth connection (without gloves) in order to discharge yourself.

• Disconnect electrical connector -1- for mechatronic unit for dual clutch gearbox -J743-. To do this, pull locking mechanism upwards -arrow-.
• Unscrew nuts -2- and -3- and remove wiring retainer from gearbox.
• Tie up wiring in area of gearbox cover.

• Unscrew upper engine/gearbox connecting bolts with a suitable socket from shock absorber set -T10179- or insert tool 18 mm -T10001-.
• If there are hose and cable connections in area of engine support eye for support bracket -10-222A-, remove these now.
• Install support bracket -10-222 A- as follows:

Required material:

Adapter -10 - 222 A /29-, qty. 2

Square tube -T40091/1-

Connecting piece -T40091/3-

Spindle from engine support supplement set -T40093 /3-

Shackle -10 - 222 A /12-

Adapter -T40093/3-6A-

• On both sides of vehicle, insert adapters -10 - 222 A /29- between upper wheel housing longitudinal member and mounting plate for wing located underneath.

Installation position:

“R” (not illustrated here) adapter is to be used on “left” side of vehicle.

Arrow -2- points in direction of travel.

• Slide connecting piece -T40091/3- onto support bracket -10-222 A-.
• Secure support bracket -10-222 A- to adapters -10 - 222 A /29-.

-A- = adapter -T40093/3-6A- (⇒ next Fig.).

• Position adapter -T40093/3-6A- on left longitudinal member directly behind filler pipe for washer fluid reservoir.

• Bolt on spindle from engine support supplement set -T40093 /3-, connect it via square tubes -T40091/1- to engine support bracket -10-222 A- and fasten the connection (⇒ previous fig.).
• Slightly take up weight of engine/gearbox assembly on engine support bracket -10-222 A-.
• Remove noise insulation → General body repairs, exterior; Rep. gr.66.
• Remove front left wheel housing liner → General body repairs, exterior; Rep. gr.66.

• Disconnect connector -1- from oil level and oil temperature sender -G266-.
• Remove subframe without steering rack → Running gear, axles, steering; Rep. gr.40.
• Disconnect both drive shafts from gearbox → Running gear, axles, steering; Rep. gr.40.

• Secure drive shaft to suspension strut with tensioning strap -T10038-.

The surface protection of the shafts must not be damaged.

Remove all bolts -1- and -2- for gearbox bracket.

• Lower engine/gearbox assembly using spindle -10 - 222 A /11- until distance -a- is obtained between gearbox housing and gearbox mounting.

Dimension -a- = 50 mm

• Remove gearbox bracket.
• Remove all connecting bolts except one which is in an easily accessible place between engine and gearbox.
• Set up gearbox support -3282- with adjustment plate -3282/59-.

• Position engine and gearbox jack -VAS 6931- or -V.A.G 1383 A- under gearbox and support gearbox. Do not raise.
• Position plate of pin under gearbox housing, not under mechatronic unit.
• Screw a pin into »rear« hole for pendulum support.
• Secure gearbox with tensioning strap -T10038- to prevent it from falling down.

The gearbox is separated from the engine in this position.

• Remove last engine/gearbox connecting bolt.
• Separate gearbox from engine, »observing selector lever cable«. Slightly tilt gearbox using outer spindle of gearbox support -3282-.

• Now slightly turn gearbox and lower it. Be sure to guide flange -1- past intermediate plate -arrow- when lowering gearbox.

Be careful of all lines when lowering gearbox.

Transporting gearbox → Chapter.

Secure gearbox to assembly stand → Chapter.

Installing gearbox → Chapter.

Brief description

The gearbox is removed downwards separately.

»From above«

»From below«:

Adjustment plate -3282/59-

Tensioning strap -T10038-

Insert tool, 18 mm -T10179-

Removal lever -80 - 200-

Adapter -T40093/3-6-, qty. 2

or Adapter -T40093/3-6A-

Not illustrated: engine and gearbox jack -VAS 6931- or -V.A.G 1383 A-

Check adapter -T40093/3-6- and adjust as necessary

• If necessary, cut off the marked area.
• Round off the front edges.
• Protect adapter against corrosion.
• Then, mark adapter -T40093/3-6- with -T40093/3-6A-.

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.
• Remove air filter housing → Rep. gr.23.
• Remove battery and battery tray → Electrical system; Rep. gr.27.

• Using removal lever -80 - 200-, lever selector lever cable -1- off gearbox selector lever.
• Remove bolts -2-, raise and tie selector lever cable together with support bracket.

Caution Risk of damage to selector lever cable. Do not bend or kink selector lever cable.

• Remove starter → Electrical system; Rep. gr.27.

It is advisable to remove the »lower« bolt first.

Caution Risk of damaging gearbox components beyond repair. Do not under any circumstances touch the contacts in the gearbox connector by hand. Electrostatic discharge can seriously damage the control unit and mechatronic unit.

• Touch earth connection (without gloves) in order to discharge yourself.

• Disconnect electrical connector -1- for mechatronic unit for dual clutch gearbox -J743-. To do this, pull locking mechanism upwards -arrow-.
• Unscrew nuts -2- and -3- and remove wiring retainer.
• Tie up wiring in area of gearbox cover.
• Remove air pipe → Rep. gr.21.

• Unscrew upper engine/gearbox connecting bolt using insert tool 18 mm -T10179-.
• Remove noise insulation → General body repairs, exterior; Rep. gr.66.
• Remove lower part of front left wheel housing liner → General body repairs, exterior; Rep. gr.66.

• Disconnect connector -1- from oil level and oil temperature sender -G266-.
• Remove subframe without steering rack → Running gear, axles, steering; Rep. gr.40.
• Disconnect both drive shafts from gearbox → Running gear, axles, steering; Rep. gr.40.

• Secure drive shaft to suspension strut with tensioning strap -T10038-.

The surface protection of the shafts must not be damaged.

• Remove windscreen wiper arms → Electrical system; Rep. gr.92.
• Remove plenum chamber cover → General body repairs, exterior; Rep. gr.50.
• If there are hose and cable connections in area of engine support eye for support bracket -10-222A-, remove these now.
• Install support bracket -10-222 A- as follows:

Required material:

Adapter -10 - 222 A /31-1-

Adapter -10 - 222 A /31-2-

Connecting piece -T40091/3-, qty. 2

Square tube -T40091/1-, qty. 2

Spindle from engine support supplement set -T40093 /3-

Adapter -T40093/3-6- or adapter -T40093/3-6A--A-

• Remove caps on threaded connections for front suspension struts.

• Fit adapter -10 - 222 A /31-1- and adapter -10 - 222 A /31-2--A- onto suspension strut mountings.

The webs -arrow- must face towards front end.

• Slide connecting piece -T40091/3- onto support bracket -10-222 A-.
• Bolt support bracket -10-222 A- to adapter -10 - 222 A /31-1- and to adapter -10 - 222 A /31-2-.

-A- = adapters -T40093/3-6A- (⇒ next fig.).

On the right in direction of travel:

• Remove fuel filter and lay to side. Do not open pipe/hose system → Rep. gr.20.

• If present, pull off wires in front area of web of longitudinal member -arrow-. Do not disconnect pipe/hose system.
• Place adapter -T40093/3-6A- onto right longitudinal member.
• If necessary, carefully unclip any pipes for air conditioning system in front area. Do not disconnect pipe/hose system → Heating, air conditioning; Rep. gr.87.

On the left in direction of travel:

• Position adapter -T40093/3-6A- on left longitudinal member directly behind filler pipe for washer fluid reservoir.

• Bolt on spindle from engine support supplement set -T40093 /3-, connect it via square tubes -T40091/1- to engine support bracket -10-222 A- and fasten the connection (⇒ previous fig.).

• Then attach spindles to engine support eyes.
• Take up weight of engine/gearbox assembly and support bracket on spindles.

Remove all bolts -1- and -2- for gearbox bracket.

• Lower engine/gearbox assembly using spindle -10 - 222 A /11- until distance -a- is obtained between gearbox housing and gearbox mounting.

Dimension -a- = 50 mm

• Remove gearbox bracket.

• Remove engine/gearbox connecting bolts -1- and -2-.

• Set up gearbox support -3282- with adjustment plate -3282/59-.

• Position engine and gearbox jack -VAS 6931- or -V.A.G 1383 A- under gearbox and support gearbox. Do not raise.
• Position plate of pin under gearbox housing, not under mechatronic unit.
• Screw a pin into »rear« hole for pendulum support.
• Secure gearbox with tensioning strap -T10038- to prevent it from falling down.

The gearbox is separated from the engine in this position.

• Remove last engine/gearbox connecting bolt.
• Separate gearbox from engine, »observing selector lever cable«. Slightly tilt gearbox using outer spindle of gearbox support -3282-.

• Now slightly turn gearbox and lower it. Be sure to guide flange -1- past intermediate plate -arrow- when lowering gearbox.

Be careful of all lines when lowering gearbox.

Transporting gearbox → Chapter.

Secure gearbox to assembly stand → Chapter.

Installing gearbox → Chapter.