Vehicles With Short Front End
Transmission, removing and installing
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 short front end)
Special tools and equipment
^ 3094 Hose clamps
^ 3184 Transmission support
^ 3184/1 Auxiliary support
^ 3227 Engine repair stand
^ 3230 Engine repair stand
^ 3250 Support
Special tools and equipment
^ 3257 Socket, 27 mm AF
^ 3282 Transmission support
^ 3282/4 Adjustment plate
^ 3282/22A Adjustment plate
^ 3336 Transmission lifting beam
^ VAG 1331 Torque wrench
^ VAG 1332 Torque wrench
Special tools and equipment
^ VAG 1383 A Engine/transmission jack
^ V/175 Socket
Modifying auxiliary support 3184/1 (for vehicles from 01.96 with short front end)
^ Create two 45° chamfers on each arm so that the auxiliary support 3184/1 for support device 3184 can continue to be hooked into the cross panel.
Dimension -a- = 5 mm
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).
^ Remove charge air cooler from lock carrier (arrows) if installed.
^ Remove radiator grille with trim frame and tilt out radiator and lock carrier toward front.
^ 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 hexagon bolt for drive axle/wheel hub.
Support device 3250 can no longer be used.
The torsion bars are relieved when vehicle is raised.
^ 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 bolts -1- and fold radiator out in direction of arrow.
^ Pull upper white connector off transmission (transmission vehicle speed sensor (VSS) -G38-).
^ 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.
^ Raise vehicle.
^ Remove noise insulation tray.
^ Pull electrical connections 1 to 3 off transmission.
1. Valve body connection
2. Vehicle speed sensor (VSS) -G68- (black connector)
3. Multi-Function transmission range (TR) switch -F125
^ Remove multi-function switch cable and holder from transmission and place to one side.
^ Remove starter.
^ Unbolt drive axles from transmission flange shafts.
^ Raise right drive axle and secure.
^ Unbolt flanged shaft bearing -A- from transmission mount -B- (arrow).
^ Pull right-hand flange shaft -C- out from intermediate shaft -D-.
^ Detach front exhaust pipe at exhaust manifold.
^ Remove bolts (arrows) for cover plate.
^ Remove nut (arrow) from torque converter (city. 3) using special tool V 175.
^ Separate left-hand wheel bearing housing/lower swivel joint bolted connection. Always replace bolts.
^ Remove bolt for left-hand shock absorber/stabilizer bar coupling rod.
^ Push left-hand shock absorber together.
^ Remove auxiliary heater end pipe, if installed.
^ Install support device 3184 to support engine/transmission:
^ Install engine support to engine block.
^ On vehicles with 5-cyl. engine, use engine support 3227.
^ Hook auxiliary support 3184/1 for support device 3184 in cross panel (arrow). If necessary, remove wiring harnesses and pipes from cross panel.
^ Install support device 3184 into auxiliary support 3184/1 and into subframe -A-. Screw spindle -C- into hole on engine mount.
^ Align support device so that the slide -B- is resting against the righthand tube (arrow).
^ Secure support device to subframe -A- and to auxiliary support 3184/1 by tightening the angle plates.
^ Relief subframe loading by raising engine/transmission by means of spindle -C-.
^ Remove pendulum support. To do this remove bolts -A- and -B-.
^ Unbolt transmission mount from body (arrow 1).
^ Lower engine using support device spindle.
^ Unscrew bearing block -A- from transmission (arrow 2).
^ Carefully swivel engine/transmission forward and lower, thereby ensuring that the selector lever cable, multi function switch and drive axles are not damaged.
Swivelling forward: turn spindle -B- to the left
Swivelling back: turn spindle -B- to the right
^ Make sure that the selector lever cable does not become tightened.
^ Unclip selector lever cable securing clips and detach selector lever cable.
^ Clamp-off ATF cooler hoses with -3094- and detach at ATF cooler.
^ Tilt engine/transmission further forward and lower.
^ Make sure sufficient clearance between engine and vehicle longitudinal member, if necessary loosen alternator and remove tensioning arm from engine.
^ Remove left-hand drive axle, ensuring multi function switch is not damaged.
^ 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-.
^ 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.
^ Lower transmissions lightly.
^ 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, ensure that both drive pins engage in the ATF pump inner wheel recesses.
^ Always replace self-locking nuts and bolts.
^ Before installing, ensure that the dowel sleeves are correctly located.
^ Before installing starter mounting bushing, check for wear and replace if necessary.
^ Before installing pendulum support bushing, check for wear and replace if necessary.
When swinging transmission in, install both drive axles in the flanged shaft and drive flange.
^ Before lifting engine/transmission, tighten bolts of bearing block -A- (arrows 2) to prescribed torque 50 Nm + 90 °.
^ After lifting engine/transmission, tighten nuts (arrow 1) to prescribed torque 55 Nm.
^ Bolt flanged shaft bearing -A- to transmission carrier -B-to prescribed torque 65 Nm.
WARNING: Do not remove support device 3184 until the bolts securing the lefthand bearing bracket have been securely tightened.
^ Enter radio code.
^ Initialize electric windows, set clock.
^ Check selector lever cable adjustment, adjust if necessary.
^ Check and top off ATF level.
^ 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