Brief description
In these vehicles, the gearbox can be removed separately downwards. The engine remains installed in the vehicle.
For Touaregs with any engine variant, it is recommended to remove the lower engine/gearbox connection bolts before removing the power unit. If possible, install the torque converter mount in advance. This advice applies to both removal and installation of the gearbox.
Removal
Remove the engine cover.
NOTE: Figure 3.28 shows the tandem type pump from below with the engine removed.
Fix a 20mm thick wooden spacer 1 with adhesive tape 2 as shown on the tandem pump (Fig. 3.28).
If the wooden spacer used is too thin or no wooden spacer is used, the gearbox may lie on the subframe during further disassembly and the gearbox will not be able to be removed.
Remove cooling system hoses 1-4 from the sound insulation on the front side of the engine (Fig. 3.29).
Unscrew the sound insulation (3 bolts).
Unscrew bolts A and remove the noise insulation holder.
Remove the sealing cover B using the 10-221 puller from the sealing flange (Fig. 3.30).
Screw the T10225 key to the crankshaft (Fig. 3.31).
It is essential to follow the sequence of disconnecting the battery.
Disconnect the ground terminal from the battery with the ignition off.
Completely remove the engine/gearbox sound insulation.
Remove noise insulation holders 1 and 2 (Fig. 3.32).
Unscrew the bolts of the cooling system hose holder on the right engine mount (Fig. 3.33).
Pull the cooling system hoses upwards as shown and secure them, for example, with welding wire, to the right engine mount (Fig. 3.34).
Remove the torque converter/driven disk bolts (6 pcs.).
Rotate the torque converter/driven disk through the engine crankshaft using the T10225 attachment by 1/3 of a turn (120°) in the direction of engine shaft rotation (Fig. 3.31).
Remove the lock washer 1 and the selector rod 2 by hand from the shift lever (fig. 3.11).
Unscrew bolts 2 and remove support 1 (Fig. 3.35).
Remove the ATF pipes from the gearbox (Fig. 3.36).
Cap the ATF lines and transmission ports with clean plugs.
Remove the ATF tube holder bolt on the gearbox (Fig. 3.37).
Remove the engine/gearbox mounting bolt before lowering the power unit (Fig. 3.38).
Removing the bolt when the gearbox is lowered is not possible due to lack of space.
Remove the transfer case.
Remove the exhaust pipe with the catalytic converter.
Remove the screen (Fig. 3.39).
Remove screen 1, unlock and disconnect plug connections 2-4 (Fig. 3.40).
Lower the gearbox a little more as follows.
Place the end of the trolley jack C on the engine and gearbox stand VA G 1383 A and place the wooden spacer B on top (Fig. 3.41).
Install the engine and gearbox support VA G 1383 A under the gearbox.
Raise the gearbox enough to remove the VW 785/1 B retaining device (used for removing and installing the transfer case) from the gearbox.
Then place a wooden spacer A, about 50 mm thick, between the gearbox and the subframe.
Make sure that the wooden spacer is not located under the ATF pipes.
Lower and set aside the VAG 1383 A engine and gearbox stand.
Unscrew nuts 1 and remove the right intake pipe holder 2 from the starter mounting bolts (Fig. 3.42).
The starter cable can be left installed.
Remove bolts 1 and remove the starter from the engine/gearbox.
Remove engine/gearbox mounting bolt 2 (Fig. 3.43).
Unscrew nut 2 of the cooling system pipe holder from bolt 3 (Fig. 3.44).
Remove engine/gearbox connection bolts 1 and 3.
Adjust the position of the gearbox stop 3282 for dismantling the automatic gearbox "09D" using the adjusting plate 3282/49.
Install gearbox support 3282 into engine and gearbox stand VAG 1383 A.
Orient the shoulders of the gearbox stop levers in accordance with the holes in the adjusting plate.
The symbols on the adjustment plate show the necessary support parts, the arrow indicates the direction of movement.
Install the VAG 1383 A engine and gearbox support with the 3282 gearbox support under the vehicle.
Secure the 3282/52 stop to the rear of the gearbox using the M10x30 bolt (Fig. 3.45).
Secure the 3282/52 stop on the left and right side of the gearbox under the oil pan (Fig. 3.46).
Then lift the gearbox up enough to allow the wooden spacer to be removed between the gearbox and the subframe.
When lowering, make sure that the ATF pipes are not pinched between the gearbox and the subframe.
Carefully lower the transmission, with the engine in contact with the wood spacer on the tandem pump and against the bulkhead.
Overview of engine/gearbox connecting bolts.
Remove the two engine/gearbox connecting bolts at the top left (Fig. 3.47).
Remove the lower engine/gearbox connecting bolts (Fig. 3.48).
Press the gearbox away from the engine (mounting bushings). In this case, squeeze the torque converter out of the driven disk from the ATF pump, do not turn the torque converter.
Mark the position of the torque converter in relation to the gearbox.
These marks are necessary during installation to ensure that the holes in the mounting bolts in the torque converter and driven disk match.
Then alternately pull the gearbox down and down.
Secure the torque converter from falling out.
(View the original on the website: VWmanual.ru)
Installation
Installation is carried out in the reverse order. The following should be taken into account.
If the ATF is contaminated or before installing a new transmission, clean the ATF cooler and ATF lines.
Clean the threads of the bolts previously coated with thread varnish with a wire brush. Then install the bolts using AMV 185 101 A1 thread varnish.
All threaded holes into which self-locking bolts/screws are screwed must be cleaned with a tap from the remains of thread varnish. Otherwise, their threads may be stripped during the next dismantling.
Always replace self-locking bolts and nuts.
Before installing a new transmission, the radiator and ATF lines must be cleaned.
Before installing the gearbox, it is necessary to ensure that the torque converter is correctly installed in the gearbox.
Before installation, check that the mounting bushings are seated correctly.
Ensure that the fitted bushings are correctly positioned between the engine and gearbox. The absence of fitted bushings will result in the engine and gearbox being out of alignment, and therefore, in the destruction of the friction bearing and the torque converter hub.
Align the marks on the gearbox and torque converter.
If there are no marks, turn the torque converter and driven plate towards each other so that the threaded hole of the torque converter and the hole of the driven plate are in the center of the starter mount.
With the gearbox lowered, tighten the two engine/gearbox connecting bolts at the top left and the connecting bolt under the starter (Fig. 3.47).
Tighten the lower engine/transmission connecting bolts.
Then raise the gearbox enough to allow a wooden spacer approximately 50 mm thick to be inserted between the gearbox and the subframe (Fig. 3.48).
Make sure that the wooden spacer is not located under the ATF pipes.
Lower the gearbox and remove the gearbox support 3282.
Tighten engine/gearbox connecting bolts 1 and 3.
Screw nut 2 of the cooling system pipe holder onto bolt 3 (Fig. 3.44).
Install the exhaust pipe/catalytic converter with the bracket.
Install the transfer case.
Install torque converter/driven disc bolts (6 pcs.)
Rotate the torque converter/driven disk through the engine crankshaft using the T10225 attachment by 1/3 of a turn (120°) in the direction of engine shaft rotation (Fig. 3.31).
Install the starter.
Tighten the remaining engine/transmission connecting bolts.
Install the screen and tighten the bolts to a torque of 10 Nm (Fig. 3.39).
Install screen 1 and tighten the bolts to 10 Nm.
Connect plug connections 2-4 (Fig. 3.40).
Tighten the ATF tube holder bolt on the gearbox (Fig. 3.37).
Remove the plugs and insert the ATF tubes into the gearbox until they stop (Fig. 3.36).
Tighten the bolt.
Install support 1.
Install bolts 2, lubricate with thread varnish, and tighten (Fig. 3.35).
Press the selector rod 2 with your hand against the gear selection rod (fig. 3.11).
When installing, do not bend the gear shift control shaft lever, otherwise it will not be possible to make precise gear shift adjustment.
Install a new lock washer 1.
Tighten the coolant hose retainer bolts on the right engine mount (Fig. 3.33).
Install noise insulation holders 1 and 2 (Fig. 3.32).
Unscrew the T10225 key from the crankshaft.
Replace the sealing cap.
Tighten the sound insulation holder bolts (Fig. 3.30).
Tighten the bolts (3 pcs.) of the noise insulation.
Install cooling system hoses 1-4 on the sound insulation (Fig. 3.29).
Remove the wooden spacer 1 and adhesive tape 2 from the tandem pump (Fig. 3.28).
It is essential to follow the sequence of disconnecting the battery.
Perform work operations after connecting the battery.
Check the selector rod adjustment and adjust if necessary.
Check the ATF level and top up the oil.
When checking the ATF level, check the ATF tube terminals for leaks (Fig. 3.36).
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