NOTE: Vehicles with V6 and V8 petrol engines, V6 TDI turbodiesel, V10 TDI and W12 petrol engines.
Short description
The 09D automatic transmission is removed together with the engine, front final drive and transfer case.
For Touareg with all engine options, it is recommended to dismantle the lower connecting bolts before removing the power unit» engine/gearbox. If possible, install the torque converter mount in advance. This advice applies both when removing and when connecting the gearbox to the engine.
There are two options for disconnecting the engine from the gearbox on the assembly table VAS 6131.
First option
Automatic gearbox 09D and transfer gearbox 1 remain bolted together. These units can be disconnected together from the engine for, for example, removal or installation of the torque converter.
In this case, the front propeller shaft 2 is unscrewed only in front of the transfer case. In this way it is possible to separate the motor on one side and the boxes on the other side of the VAS 6131 assembly table from each other.
Second option
First, the transfer case is removed from the table, then the automatic transmission. In this way, installation work can be carried out on an automatic transmission. To do this, you first need to unscrew the front driveshaft on both sides, the transfer case 1 is disconnected and removed from the table. Only then is the automatic transmission disconnected from the engine and, if necessary, also removed from the table.
This second option is described below.
Removing
With any engine options, it is recommended to remove the lower engine / gearbox connecting bolts before dismantling the power unit.
If possible, install the torque converter mount as soon as possible.
Removing the engine from the gearbox (cars with petrol engines V6 and V8)
Remove the starter (pic. 3.50).
Unbolt the torque converter from the drive plate.
Vehicles with V10 TDI turbodiesel engine
NOTE: The starter cable must not be removed until the connecting bolt has been removed (pic. 3.51).
On these vehicles, the torque converter mount and lower engine/gearbox connecting bolts must be installed with the power unit installed.
Vehicles with V6 TDI turbodiesel engine
It is impossible to dismantle the starter until the torque converter bolts are installed.
Continuation for all cars
Make sure that the support for the automatic transmission is min. 2 plates VAS 6131/ 1 assembly table under the oil pan (pic. 3.52).
Remove the propeller shaft between the transfer case and the front final drive from the transfer case.
To hold the cardan shaft, you can use the support T10172.
Also 2 bolts max. M10 (pic. 3.53) or counterholder T10172.
Lift the transfer box with a crane (pic. 3.54).
Disconnect the transfer case and set aside.
Vehicles with V6 TDI turbodiesel engine
Remove the catalytic converter and particle filter 1 from the turbocharger.
Always replace the nuts on the turbocharger.
Remove tubes of system of cooling 2 from a case of the hydrotransformer 2 bolts.
Remove speed sensor 3 (pic. 3.55).
Unscrew the ATF pipes.
If this operation has not yet been completed, remove the heat-insulating shield on the left of the gearbox.
Further, when disconnecting the V6 TDI engine from the gearbox, make sure that the engine does not tip over.
Therefore, lift the engine with the crane VAS 6100 and suspension tool 3033. Place the crane on the side of the table.
If there is no second crane, disconnect the engine and gearbox, then support the engine with suitable means.
Vehicles with W12 engine
Remove all catalytic converters from the exhaust manifold.
Unscrew the ATF pipes.
If at the time of the start of dismantling the power unit this operation was not performed, unscrew the torque converter from the driven disk.
Continuation for all cars
Before disconnecting the engine from the gearbox, take measures to ensure that the engine does not turn over.
This operation will be shown again using the example of a V6 TDI engine.
If there is no second crane, disconnect the engine and gearbox, then support the engine with suitable means.
Raise the gearbox with a crane.
Unscrew the ATF pipes.
Remove all engine/gearbox connecting bolts.
Carefully push the gearbox away from the engine.
Make sure that the torque converter with the gearbox is pressed by the drive plate.
Installation
Installation is carried out in the reverse order.
Check selector lever adjustment, adjust if necessary.
After installation, check the ATF level, add oil if necessary and adjust the wheel alignment.
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