Volkswagen Golf Variant / Jetta. Manual - part 115

 

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Volkswagen Golf Variant / Jetta. Manual - part 115

 

 

The connector on the transmission must not be damaged

when removing and installing the transmission. Replace the

wiring harness in the transmission if the connector gets dam‐

aged. Refer to 

⇒ “4.1 Overview - Valve Body”, page 128

 .

Pay attention to the torque converter. It must be removed to‐

gether with the transmission. Secure the torque converter

with, for example a wire -A- to prevent it from falling out.

Bear in mind that when installing a new transmission, the cable

bracket and the selector lever cable bracket for example must

be replaced.

Note

If the needle bearing in the crankshaft is damaged, the gears

will no longer shift correctly.

If it is not damaged, coat it lightly with High Temperature

Grease . Refer to the Parts Catalog.

Grease the transmission driveshaft pins (not the splines) light‐

ly.

7.3

Transmission, Removing, Jetta MY

2011, 2.5L 125 kW

– Before removing, print out the diagnostic protocol for this ve‐

hicle »if possible«. Affix the protocol on to transmission before

sending back the removed transmission in the usual way.

Special tools and workshop equipment required
♦ Engine and Gearbox Jack - VAS6931-
♦ Socket - Sw15 - V/175-
♦ Transmission Support - 3282-
♦ Drive Axle Wedge Tool - T10161-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
♦ Transmission Support - Mounting Plate 36 - 3282/36-
♦ Engine Support Bridge - 10-222A-
♦ Hose Clamps - Up To 25mm - 3094-
♦ Tensioning Strap - T10038-
♦ Engine Support - Basic Set - T40091-
Removing
– Move the selector lever into »P«.
– See if a coded radio is installed. If so, obtain the anti-theft code.
– Disconnect the battery ground cable. Refer to ⇒  Electrical

Connecting .

Gr.  24 ; Air Filter; Air Filter Housing, Removing and Installing .

7. Transmission, Removing and Installing, Jetta from MY 2011    

91

from the throttle valve.

– Remove the battery and the battery tray. Refer to ⇒  Electrical

Equipment; Rep. Gr.  27 ; Battery; Battery, Removing and In‐

stalling .

– To remove the selector lever cable from the transmission, re‐

lease the selector lever cable -arrows 1- and then remove it

from the cable bracket -arrow 2-.

Note

Do not use pliers because the mounting tabs on the cable

bracket could break off.

Do not bend or kink the selector lever cable.

– Pry the selector lever cable -1- off the selector shaft lever -3-

using for example an open end wrench -2-.

92

and remove the hoses form the ATF cooler.

– Disconnect the connections from the transmission and starter.
♦ Multifunction transmission range switch
♦ Starter

– Remove the wiring bracket -1- from the starter bolt -arrow-.
– Remove the upper starter bolt.
– Remove the upper engine/transmission connecting bolts.
– Remove the plenum chamber cover. Refer to ⇒  Body Exterior;

Rep. Gr.  50 ; Plenum Chamber Cover; Plenum Chamber

Cover, Removing and Installing .

So that engine and transmission can be supported:

– Remove the wires -1- from the transport strap -3-.
– Remove the transport strap -3- from the engine -2- and pull it

out of the eye -arrow-.

– Insert a Engine/Gearbox Support Shackle (2 pc.) - 10-222A/

12- in »this« eye.

– Remove the bolts -arrows- for the left and right lock carrier

retaining brackets.

7. Transmission, Removing and Installing, Jetta from MY 2011    

93

gine Support 28 - 10-222A/28- and replace with the Engine

Support Bridge - Engine Support 28-2 - 10-222A/28-2- .

– Remove the bolts -arrows- for securing the engine support

bridge on the lock carrier from the Engine Support Bridge -

Engine Support 28-2 - 10-222A/28-2- .

• Use the bolts in the Engine Support Bridge - Engine Support

28-2 - 10-222A/28-2- for attaching the Engine Support Bridge

- Engine Support 28 - 10-222A/28- . Not the bolts for the re‐

taining bracket.

– Install the Engine Support Bridge - Engine Support 28 -

10-222A/28- and tighten the bolts to 8 Nm -arrows-.

Caution

A second technician is needed to mount the Engine Support

Bridge - 10-222A- on the vehicle to prevent the Engine Support

Bridge - 10-222A- from tipping.

– Install the Engine Support Bridge - 10-222A- as shown.
– First slide the Engine Support - Basic Set - Movable Joints -

T40091/3- -2- onto the Square Pipe from the Engine Support

Bridge - 10-222A- .

– Mount the Engine Support Bridge - 10-222A- on the suspen‐

sion strut towers and have a second technician hold it to

prevent it from tipping.

– Push the Engine Support - Basic Set - Square Pipe -

T40091/1- -5- from the front left and right through the Engine

Support Bridge - Engine Support 28 - 10-222A/28- -6- and

place on each side of the Engine Support - Supplement Kit -

Movable Joint - T40093/4- -4-.

– Additionally attach the Engine Support - Bracket w/Spindle

and Hook - 10-222A/10- -7- on the right Engine Support - Basic

Set - Square Pipe - T40091/1- .

– Push the Engine Support - Basic Set - Rail with Holes -

T40091/2- -9- with the Engine Support - Supplement Kit -

Mount - T40093/5- -10- in the Engine Support - Supplement

Kit - Movable Joint - T40093/4- -4-.

– Install the locking pins into the Engine Support - Basic Set -

Rail with Holes - T40091/2- -9- and secure it with the cotter

pins.

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