Vehicles With Long Front End
Transmission, removing and installing
Removing and installing transmission on vehicles from 01.96 with long front end -
All Eurovan from 01.96
On Eurovan from 01.96, the front end and also the assembly mounts have been modified.
The front end can be either long or short front end version.
The transmission mounts on these vehicles have also been modified (pendulum support). From 01.96, drive to the right-hand drive axle is via an exposed flange shaft.
Support device 3250 can no longer be used.
The torsion bars are relieved when vehicle is raised.
Differences between EuroVan with long and short front end from 01.96
1. EuroVan with short front end
^ Character line (arrow) on upper wing.
2. EuroVan with long front end
^ This EuroVan is 90 mm (dimension -a-) longer than a short front end vehicle.
^ No character line on upper wing.
Transmission, removing and installing (vehicles from 01.96 with long front end)
Special tools and equipment
^ 10-222 A Support
^ 10-222 A/2 Special hook
^ 10-222 A/3 Adapter
^ 10-222 A/6 Supports
^ 10-222 A/7 Auxiliary hooks
^ 2024 A/2 Lifting eye
Special tools and equipment
^ 3094 Hose clamps
^ 3257 Socket, 27 mm AF
^ 3282 Transmission support
^ 3282/22A Adjustment plate
^ 3336 Transmission lifting beam
^ 3407 Bracket
Special tools and equipment
^ VAG 1331 Torque wrench
^ VAG 1332 Torque wrench
^ VAG 1383 A Engine/transmission jack
^ VAS 5085 Step-ladder
^ V/175 Socket
Removing
^ First check whether a coded radio is installed. If this is the case obtain the anti-theft coding.
^ Remove battery covering.
^ With the ignition switched off disconnect the battery Ground strap (in engine compartment and if installed, under driver's side).
^ With the vehicle stood on hard, level ground, loosen left-hand drive axle/wheel hub bolt -arrow- and left-hand wheel securing bolts.
^ Lift vehicle until the load on the front axle is relieved.
^ Remove left wheel.
^ Remove hex bolt for drive axle/wheel hub.
^ Remove upper engine/transmission connecting bolts.
Note: Mark position of engine/transmission connecting bolts before removal and only use bolts of same length when replacing.
^ Pull upper connector off transmission (transmission vehicle speed sensor (VSS) -G38
^ Raise vehicle.
^ Measure distance from nut face to end of torsion bar threaded rod -a- and note.
^ Relieve tension on torsion bar with special tool 3257.
^ Remove noise insulation tray.
^ Remove electrical connections (arrows) at transmission.
^ Pull connector off speedometer sender.
^ Remove starter.
^ Unbolt drive axles from transmission flange shafts.
^ Raise right drive axle and secure.
Vehicles with 6-Cyl. injection engines
^ Remove transmission carrier -A- for bearing of right-hand flanged shaft -B- (arrows).
^ Pull out flanged shaft.
^ Detach front exhaust pipe at exhaust manifold.
^ Remove bolts (arrows) for cover plate.
^ Remove nut (arrow) from torque converter (Qty. 3) using special tool V
^ Remove pendulum support -1-; to do this, remove bolts -arrow A- and -arrow B-.
^ Separate left-hand wheel bearing housing/lower swivel joint bolted connection. Always replace bolts.
1 -14 mm AF multi-point key (e.g. Hazet 990)
^ Remove bolt for left-hand shock absorber/stabilizer bar coupling rod.
^ Press drive axle out of wheel bearing housing.
^ Push left-hand shock absorber together.
^ Remove left-hand drive axle, ensuring multi function switch is not damaged.
^ Remove auxiliary heater end pipe, if installed.
Vehicles with 6-Cyl. injection engines
^ Remove engine/transmission securing bolt (arrow).
^ Install retainer 3407 to engine.
^ Install support device 10-222A in conjunction with hooks 10-222 A/6.
^ Hook 10-222 A/2 hook and additional hook 10-222 A/7 in left-hand support spindle.
^ Hook additional hook 10-222 A/7 in retainer 3407 (=Illustration N340483).
^ Hook 10-222 A/2 hook in right-hand support spindle and on engine.
^ Pre-tighten engine/transmission assembly on the spindles.
^ Unclip selector lever cable securing clips and detach selector lever cable.
^ Clamp-off ATF cooler hoses with -3094- and detach at ATF cooler.
^ Set up transmission support 3282.
The transmission support 3282 is set up with the adjusting plate 3282/22A for removal of automatic transmission 01 P.
^ Bolt on support elements -A-, as illustrated on adjustment plate.
Note:
The support element -C- can be used with the corresponding hole -arrow- in the adjustment plate to remove the transmission in cases where the engine has a metal oil sump.
Once the torque converter cover has been removed, the support element -C- should be bolted tight to the torque converter housing.
^ Move jack VAG 1383 A with transmission mount 3282 under the transmission and support transmission.
The arrow symbol -B- on the adjustment plate points in direction of normal travel.
^ Secure transmission support 3282 with drilled plate to the pendulum support bushing -arrow-.
^ Unbolt transmission mount from body (arrow 1).
Note: To remove securing nuts use step-ladder VAS 5085.
^ Carefully lower engine/transmission assembly via spindles of support device and, at the same time, via the engine/transmission jack VAG 1 383 A.
^ Unbolt bearing block with transmission mount from transmission (arrow 2).
^ Remove lower engine/transmission connecting bolts.
^ Press transmission off engine, when doing this, press torque converter out of drive plate.
^ Press torque converter against ATF pump.
^ Swivel transmission and carefully lower.
^ Secure torque converter to prevent it falling out.
Transporting the automatic transmission
Special tool 3336 may be used to transport the automatic transmission and also when setting up transmission support 3282.
^ Secure special tool 3336 to transmission housing flange.
^ Position pins so that 8 holes are visible in chain direction.
Installing
Installation is performed in the reverse order.
When installing the torque converter, make sure that both drive pins engage in the ATF pump inner wheel recesses.
^ Always replace self-locking nuts and bolts.
^ Before installing, make sure that the dowel sleeves are correctly located.
^ Before installing starter mount bushing, check for wear and replace if necessary.
^ Before installing pendulum support bushing, check for wear and replace if necessary.
^ Install left-hand drive axle.
^ Before lifting engine/transmission assembly, tighten bearing block bolts (arrows 2) to prescribed torque 50 Nm + 90 °.
^ Carefully lift engine/transmission assembly via spindles of support device 10-222 A and via engine/transmission jack VAG 1383 A.
^ Tighten nuts (arrows 1 ) after lifting engine/transmission assembly to prescribed torque 55 Nm.
WARNING: Do not remove support bar 10-222A until the bolts securing the left and right assembly mounts have been tightened to torque setting.
^ First tighten transmission carrier -A- on engine to 50 Nm, then on flanged shaft bearing -B- to 25 Nm.
^ Replace selector cable anchorage locking washer.
^ Check selector lever cable adjustment, adjust if necessary.
^ Check and top off ATF level.
^ Enter radio code.
^ Initialize electric windows, set clock.
^ Perform On Board Diagnostic (OBD) and initiate basic setting.
Tightening torques
Left-hand transmission mount
Nuts-arrows 1- 55 Nm
Bolts -arrows 2- 50 Nm + 90°
Rear transmission mount
Refer to Suspension, Service and Repair, Front Suspension, I - Subframe/Stabilizer/Torsion Bar/Control Arm/Shock Absorber.
I - Subframe/Stabilizer/Torsion Bar/Control Arm/Shock Absorber
Note:
Install engine/transmission mounts stress-free.
Transmission carrier for flanged shaft bearing -A
to engine 40 Nm
to bearing/flanged shaft 25 Nm
Torque converter to drive plate 60 Nm
Transmission to engine bolt M8 23 Nm
Transmission to engine bolt M10 60 Nm
Transmission to engine bolt M12 80 Nm
Cover plate to transmission 15 Nm
Transmission mtg. to bearing housing M25 8 Nm
Transmission mtg. to engine M10 40 Nm
Lower control arm to wheel bearing housing
Refer to Suspension, Service and Repair, Front Suspension, II - Upper and Lower Control Arms.
II - Upper and Lower Control Arms
Drive axle to flanged shaft and wheel hub
Refer to Suspension, Service and Repair, Front Suspension, III - Wheel Bearing/Drive Axle.
III - Wheel Bearing/Drive Axle
Shock absorber to wishbone
Refer to Suspension, Service and Repair, Front Suspension, I - Subframe/Stabilizer/Torsion Bar/Control Arm/Shock Absorber.
I - Subframe/Stabilizer/Torsion Bar/Control Arm/Shock Absorber
Wheel bolts to wheel hub
Refer to Wheels and Tires, Wheel Fastener, Application and ID.
Application and ID