Transmission, Removing, 2.0L TDI Engine (Pr-T98 / Ea288 EVO)

Special tools and workshop equipment required

Hose Clamps - Up To 25 mm: 3094

Fig 1: Hose Clamps
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Torque Wrench 1332 Insert - Ring Wrench - 16mm: VAG1332/14

Fig 2: Identifying Ring Spanner Insert AF 16 VAG 1332/14
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Hose Clip Pliers: VAS6362

Fig 3: Hose Clip Pliers
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Engine and Gearbox Jack: VAS6931

Fig 4: Engine and Gearbox Jack VAS6931 or VAG1383A
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Torque Wrench Adapter: VAS6948

Fig 5: Identifying Torque Wrench Adapter VAS6948
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Tensioning Strap: T10038

Fig 6: Identifying Tensioning Strap T10038
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Tensioning Strap: T10523

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Gearbox Support: T40173A

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Wrench - 21mm: T40263

Fig 7: Identifying Wrench - 21mm
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Adapter: T40405

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Gearbox Support: T40173A Preparing:

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-- The bracket -arrow- must be turned so that the longer side faces upward, as shown.

Procedure

-- Disable the ATF pump and drain the hydraulic pressure reservoir. Refer to ATF PUMP, DEACTIVATING AND DRAINING THE HYDRAULIC PUMP RESERVOIR .

-- Switch the ignition off.

-- Bring the front wheels into the straight-ahead position and remove. Refer to the appropriate Service Information .

Fig 8: Transmission Maximum Tilt

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CAUTION:

Risk of damaging the transmission by mixing ATF and transmission fluid (MTF) through the same bleeder.

The transmission filled with ATF and (MTF) transmission fluid must be tilted a maximum of 15° in lateral and longitudinal direction.
If more of an incline is needed, then the ATF and (MTF) transmission fluids must be drained. Refer to ATF, DRAINING AND FILLING and Refer to TRANSMISSION FLUID, DRAINING AND FILLING .

-- Disconnect the battery ground cable. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the subframe crossbrace. Refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

AWD Vehicles

-- Remove the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

Continuation for All Vehicles

-- Remove the front exhaust pipe. Refer to OVERVIEW - MUFFLER - 2.0L (DMSA) , OVERVIEW - MUFFLER - 2.0L (DPAA) or OVERVIEW - MUFFLER - 3.0L .

-- Remove the plenum chamber bulkhead. Refer to PLENUM CHAMBER BULKHEAD, REMOVING AND INSTALLING .

-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING - 2.0L (DMSA) , AIR FILTER HOUSING, REMOVING AND INSTALLING - 2.0L (DPAA) or AIR FILTER HOUSING, REMOVING AND INSTALLING - 3.0L .

-- Loosen the screw-type clamp -arrow- for the particulate filter.

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WARNING:

There is a risk of injury from flying soot particles.

Irritation and injury to skin and eyes possible.

Wear protective eyewear.
Wear safety gloves.

-- Loosen the screw-type clamps -arrows-, and remove the EGR pipe -1-.

-- Remove the bolts -5- and nuts -3-, and remove the bracket -2-.

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-- Remove the bolts -2 through 5- connecting the engine to the transmission that are accessible from above.

Fig 9: Transmission Mounting Bolts and Alignment Sleeves (4-Cylinder TDI Engine)

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-- To catch escaping coolant, place a cloth underneath.

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-- Loosen the hose clamps -arrows- and then disconnect and remove the coolant hoses with Hose Clamps - Up To 25mm: 3094 .

-- Install the left tower brace. Refer to TOWER BRACE, REMOVING AND INSTALLING .

-- Tie up the particulate filter as shown using the Tensioning Strap: T10038 .

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-- Support the engine in the installation position. Refer to ENGINE, SUPPORTING IN INSTALLATION POSITION 2.0L (DMSA) , ENGINE, SUPPORTING IN INSTALLATION POSITION 2.0L (DPAA) or ENGINE, SUPPORTING IN INSTALLATION POSITION 3.0L .

-- Remove the left subframe shield. Refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

-- Remove the bolts -arrows- and free up the parking lock emergency release cable -1-.

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-- Remove the right drive axle cover. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

-- Remove the left and right drive axle from the transmission flange shaft and tie it up toward the rear. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Remove the steering intermediate shaft from the steering gear and then push together. Refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

-- Remove the lower cover -1- from the transmission in direction of -arrow-.

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-- Position the Wrench - 21mm: T40263 and Adapter: T40405 on the vibration damper.

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The recess -2- must align with the "TDC" marking -1- on the vibration damper.

CAUTION:

Risk of destroying the engine by the timing mechanism skipping.

Turn the crankshaft only in the direction of engine rotation -arrow-.

-- Counterhold the crankshaft on the vibration damper.

-- Remove the three bolts -arrow- on the drive plate -1-. To do so, turn the crankshaft an additional 120° turn in the direction of engine rotation.

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CAUTION:

There is a risk of destroying the transmission control module (Mechatronic) with electrostatic discharge.

Always "discharge" the static electricity before working with connectors. Do this by touching a grounded object, for example vehicle ground, the heater or the hoist.
Do not touch connector terminals in the transmission connector with hands.

-- Disconnect the connectors -1, 2 and 3- and free up the wires.

-- Remove the bolt -1- using the Torque Wrench 1332 Insert - Ring Wrench - 16mm: VAG1332/14 and the Torque Wrench Adapter: VAS6948 .

Fig 10: Transmission Mounting Bolts and Alignment Sleeves (4-Cylinder TDI Engine)

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-- Remove the starter slightly from the transmission and leave it in the installation position.

-- Remove the remaining bolts -6 through 9- on the transmission connection to the engine.

-- Position the Engine and Gearbox Jack: VAS6931 -1- with the prepared Gearbox Support: T40173A -2- on the bottom on the transmission using the Tensioning Strap: T10523 -3-, s shown in the illustration.

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-- Remove the tunnel crossmember. Refer to TUNNEL CROSSMEMBER, REMOVING AND INSTALLING .

-- Push the transmission off the engine and lower it carefully using the Engine and Gearbox Jack: VAS6931 and pay attention to the wires while doing so.