00 technical data - planet

TRANSMISSION

Automatic transmission 09L, all wheel drive

00 TECHNICAL DATA

TRANSMISSION IDENTIFICATION

The "6-speed automatic transmission 09 all wheel drive " is installed in combination with various engine types, and is identified accordingly on the transmission type plate. Application --> Code letters, transmission application, ratios, equipment.

The transmission code letters are given on the type plate - arrow - located on bottom front of transmission next to 16-pin connector.

Fig. 1: Identifying Type Plate Courtesy of VOLKSWAGEN UNITED STATES, INC.

The type plate lists the following information:

1. Serial number of transmission

2. Part number

3. Transmission designation, in this example 6HP19

4. Code letters, in this example GZV

Additional data are production-related.

NOTES ON THE AUTOMATIC 6-SPEED TRANSMISSION 09L

Notes on the automatic 6-speed transmission 09L

NOTE:� The code letters for the transmission are also given on the vehicle data

stickers.

2008 Audi A6 Quattro

TRANSMISSION Automatic transmission 09L, all wheel drive



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Transmission

The 6-speed automatic transmission 09L (all wheel drive) has six hydraulically activated forward gears. When the lock-up clutch is closed these forward gears become mechanically driven gears by cutting out the torque converter slip.

Torque converter

The torque converter is equipped with a slip-controlled lock-up clutch.

Mechatronics unit

The mechatronics unit incorporates the hydraulic control system, the electronic Transmission Control Module (TCM) J217 , the Multi-Function Transmission Range (TR) Switch F125 and the sensors and actuators as a complete unit. The mechatronics unit is installed in the transmission within the oil pan.

Transmission Control Module (TCM) J217

The control module is part of the mechatronics unit in the transmission.

The switching points are calculated automatically (depends on driving situation and driving resistance).

Advantages:

� Gear changes are timed for maximum fuel economy.

� Maximum engine output is always available

� Individual adaptation of gear change points in all driving situations

� Gear change points are infinitely variable

Self-diagnosis

Before performing repairs to the automatic transmission, determine the cause of the fault as precisely as possible using "Guided fault finding".

"Guided fault finding" is performed using the vehicle diagnostic, testing and information system VAS5051.

Gearshift point variations for hills

An additional gear change map automatically selects gear changes for hills depending on accelerator pedal position and driving speed.

� Gear change map for extreme uphill stretches is matched to engine output

� Gear change map for extreme downhill stretches is matched to the braking effect of the engine

� The engine braking effect can also be fully exploited via a specific gear, e.g. on hills when towing a trailer, by directly selecting a gear with the tiptronic.



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CODE LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT

Code letters, transmission application, ratios, equipment

Application of mechatronics unit according to transmission code letters.

Application of mechatronics unit according to transmission code letters.

Automatic transmission 09L 09LTransmission Code letters GUT HAV Manufactured 01.04 06.04 02.04 08.04Torque converter Code letters D76 H77Application Model Audi A6 2005 --> Audi A6 2005 -->

Engine 4.2 V8 engine 247 kW

3.2 V6 engine 188 kW

Electronic Power Control (EPC) system (electronic throttle) With electronic throttle

With electronic throttle

Primary drive 26 : 28 = 0.929 33 : 29 = 1.138Spur gear drive to front axle 31 : 29 = 1.069 31 : 29 = 1.069Front axle bevel gearing 30 : 9 = 3.333 32 : 11= 2.909Overall front drive ratio = Primary drive x spur gear drive x bevel gearing

3.309 3.539

Rear axle bevel gearing 32 : 9 = 3.556 31 : 10= 3.100Overall rear drive ratio = Rear axle bevel gearing x primary drive 3.302 3.528

Automatic transmission 09L 09LTransmission Code letters HLK HLL Manufactured from 09.04 05.05 06.04 05.05Torque converter Code letters H77 D76Allocation Model Audi A6 2005 --> Audi A6 2005 -->

Engine 3.2 V6 engine 188 kW

4.2 V8 engine 247 kW

Electronic Power Control (EPC) system (electronic throttle) With electronic throttle

With electronic throttle

Primary drive 33 : 29 = 1.138 26 : 28 = 0.929Spur gear drive to front axle 31 : 29 = 1.069 31 : 29 = 1.069Front axle bevel gearing 32 : 11= 2.909 30 : 9 = 3.333Overall front drive ratio = Primary drive x spur gear drive x bevel gearing 3.539 3.309

Rear axle bevel gearing 31 : 10= 3.100 32 : 9 = 3.556Overall rear drive ratio = Rear axle bevel gearing x primary drive

3.528 3.302



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REAR FINAL DRIVE IDENTIFICATION

Rear final drive identification

The final drive 01R is allocated to the automatic transmission 09L all wheel drive.

Assembly allocation --> 00 TECHNICAL DATA .

Fig. 2: Locations Of Final Drive Identification Courtesy of VOLKSWAGEN UNITED STATES, INC.

Location on final drive

Code letters and date of manufacture - arrow1 -

Final drive 01R - arrow2 -

Fig. 3: Final Drive 01R Courtesy of VOLKSWAGEN UNITED STATES, INC.

Final drive 01R - arrow2 -



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Fig. 4: Rear Final Drive Identification Courtesy of VOLKSWAGEN UNITED STATES, INC.

Final drive code letters and date of manufacture - arrow 1 -

Additional data is production-related.

Code letters, ratios, capacities --> 00 TECHNICAL DATA .

CAPACITIES

Planetary gearbox

ATF is available as a replacement part.

Container size 1.0 ltr. Part No.G 055 005 A2

Use only the correct type of ATF (available as a replacement part) for the planetary gearing in automatic transmission09L. Other oils cause faults and/or failure of the transmission.

� Checking ATF level in planetary gearbox --> ATF level, checking and correcting.

Example: EXZ 26 11 02 I I I I I I I I Code letters Day Month Year of manufacture (2002)

Capacities Planetary gearbox Automatic transmission

Initial filling 9.8 ltr. 09LChange interval

No changing Lifetime filling: change only after repair, approx. 8 liters if oil pan has been removed

Lubricant ATF (Shell ATF M-1375.4)



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Front final drive

Gear oil SAE 75 W 90 (synthetic oil) is available as a replacement part in the following container sizes:

� 0.5 ltr. - Part No.G 052 145 A1

� 1.0 ltr. - Part No.G 052 145 S2

� Checking oil in front final drive --> Front final drive gear oil.

Transfer gear

Gear oil SAE 75 W 90 (synthetic oil) is available as a replacement part in the following container sizes:

� 0.5 ltr. - Part No.G 052 145 A1

� 1.0 ltr. - Part No.G 052 145 S2

� Check transfer gear oil --> Transfer gear oil level.

Rear final drive

� Check gear oil in rear final drive --> 39 FINAL DRIVE, REAR DIFFERENTIAL .

Capacities and specifications --> 00 TECHNICAL DATA .

NOTES ON TOWING

Notes on towing

Capacities Front final drive Automatic transmission

Initial filling 1.1 ltr. 09LChange interval

No change required Lifetime filling: change only after repairs, up to 1.1 liters if differential cover has been removed

Lubricant Gear oil SAE 75 W 90 (synthetic oil)

Capacities Transfer gearAutomatic

transmissionInitial filling 0.55 ltr. 09LChange interval

No change required Lifetime filling: change only after repairs, up to 0.55 liters if Torsen differential cover has been removed.

Lubricant Gear oil SAE 75 W 90 (synthetic oil)

CAUTION: When vehicle is being towed, the selector lever must be set to position "N" and the vehicle must not to be towed for more than 50 km or at a speed in excess of 50 km/h, as the transmission would otherwise be destroyed.



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REPAIR INSTRUCTIONS

Contact corrosion

� Contact corrosion can occur if non-approved fasteners are installed on the vehicle (bolts, nuts, washers etc.).

� For this reason, all fasteners used are treated with a special surface coating. These parts can be identified by their greenish color.

� Rubber, plastic and adhesives also consist of non-conductive materials.

� If you are not sure whether used parts can be re-installed, always install new parts.

General repair instructions

The maximum possible care and cleanliness and proper tools are essential for satisfactory and successful transmission repairs. The usual basic safety precautions also naturally apply when carrying out vehicle repairs.

A number of generally applicable instructions for the various repair procedures - which were previously repeated at numerous places in the article - are summarized here. They apply to the work described in this article.

Special tools

For a complete list of special tools used in this article "Special tools".

Jacking mode (vehicles with pneumatic suspension)

Before raising the vehicle on a platform (wheels off the ground) you must first activate the jacking mode --> 43 - SELF LEVELING SUSPENSION .

Manual release of the selector mechanism

If the battery has been removed or is empty and you wish to tow or push the vehicle please note that you will have to manually release the selector mechanism from position "P" in order to be able to move it from "P" to "N" --> Operating manual selector mechanism release.

Transmission

NOTE:� It is not possible to start the engine by means of tow-starting, for instance

in the case of insufficient battery charge or if starter is not working.

CAUTION:� Use only Genuine Audi parts. � Accessories must be approved by AUDIAG. � Damage resulting from contact corrosion is not covered by the

warranty.



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� Read the rules when working on the automatic transmission --> Read the rules. � Do not run engine or tow vehicle with oil pan removed or when there is no ATF in the transmission.

� If transmission has been removed from vehicle, secure torque converter to prevent it from falling out.

� Thoroughly clean all joints and surrounding areas before disassembling.

� Before installing transmission check position of torque converter.

� When installing transmission ensure dowel sleeves are correctly seated.

� Carefully cover or seal open components if repairs cannot be carried out immediately.

� When installing a new automatic transmission, check the following fluid levels and top off if necessary: ATF in the planetary gearbox --> ATF level, checking and correcting , the gear oil in the front final drive --> Front final drive gear oil , the gear oil in the transfer gear --> Transfer gear oil level.

� When installing a new rear final drive, check the oil level in the rear final drive and top off if necessary. Capacities and specifications --> 00 TECHNICAL DATA .

O-rings, oil seals, gaskets

� Always install new O-rings, oil seals and gaskets.

� After removing gaskets and seals, always inspect the contact surface on the housing or shaft for burrs resulting from removal or for other signs of damage.

Fig. 5: Identifying Space Between Oil Seal Sealing Lips Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Before installing oil seals, fill the space between the sealing lips - arrow - about half full with grease G 052 128 A1 .

� The open side of the oil seals faces toward the side with fluid filling.

� Before installing, lightly lubricate outer circumference of seal and sealing lips with ATF or gear oil, depending on location.

� Lightly lubricate O-rings with ATF before installation to prevent them getting crushed during assembly.

� Use only ATF in ATF area. Other lubricants will cause the transmission hydraulics to malfunction.



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� When installing a new oil seal, position the seal in the housing so that sealing lip does not contact the shaft in the same place as the old seal (make use of insertion depth tolerances).

� Replace paper gaskets, clean all sealing surfaces thoroughly and remove previous gaskets completely.

� After installing, check the relevant fluid levels and top off if necessary: ATF in planetary gearbox --> ATF level, checking and correcting , gear oil in front final drive --> Front final drive gear oil , transfer gear oil --> Transfer gear oil level , gear oil in rear final drive --> 39 FINAL DRIVE, REAR DIFFERENTIAL

Nuts, bolts

� Loosen bolts in reverse sequence to the specified tightening sequence.

� Nuts and bolts which secure covers and housings should be loosened and tightened in diagonal sequence and in stages if no tightening sequence is specified.

� The tightening torques stated apply to non-oiled nuts and bolts.

� Always replace self-locking bolts and nuts.

� Use a wire brush to clean the threads of bolts which are secured by a locking compound. Then apply locking fluid AMV 185 101 A1 to bolts before installing.

� Threaded holes which take self-locking bolts or bolts coated with locking fluid must be cleaned (using a tap or similar). Otherwise there is a danger of the bolts shearing when subsequently being removed.

Retaining rings/circlips

� Do not over-stretch circlips.

� Always renew circlips which have been damaged or over-tensioned.

� Retaining rings/ circlips must be properly seated in the base of the groove.

Bearings

� Lubricate bearings with gear oil or ATF, depending on location.

Mechatronics unit

� Replace the transmission if any of the shift elements are scorched.

� Allocate mechatronics unit according to transmission code letters.

CAUTION:� Before touching or removing the mechatronics unit, always

discharge any static electricity by touching vehicle ground or other grounded object by hand.

� Never touch contacts in 16-pin connector - B - by hand, as static discharge would damage the control module and mechatronics unit.



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Fig. 6: VAS 5051 Vehicle Diagnosis, Testing & Information System Courtesy of VOLKSWAGEN UNITED STATES, INC.

Guided fault finding, vehicle self-diagnosis and testing system

� Before servicing the automatic transmission, the exact cause of the failure must be determined as precisely as possible via the vehicle diagnostic, testing and information system VAS5051 in the modes "Guided Fault Finding" , "vehicle self-diagnosis" and "testing system".

READ THE RULES

Read the rules

� Observe the general repair instructions --> General repair instructions.

� Thoroughly clean all joints and surrounding areas before disassembling.

� Place removed parts on a clean surface and cover them. Use sheeting and paper. Use lint-free cloths.

� Carefully cover or seal open components if repairs cannot be carried out immediately.

� Only install clean components: do not remove replacement parts from packaging until just before installation.

32 TORQUE CONVERTER

TORQUE CONVERTER

Torque converter

CAUTION: Before installing transmission check position of torque converter.

NOTE:� Read the rules when working on the automatic transmission --> Read the

rules . � General repair instructions --> General repair instructions .



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Torque converter, identification

Fig. 7: Torque Converter, Identification Courtesy of VOLKSWAGEN UNITED STATES, INC.

There are various types of torque converter. They are marked with code letters - arrow -.

Torque converter/transmission application --> Code letters, transmission application, ratios, equipment.

Torque converter, draining

Special tools, testers and auxiliary items required

Fig. 8: Oil Extractor V.A.G 1358 A Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Oil extractor V.A.G1358A

� Oil extractor probe V.A.G1358A/1

� Apply thin coat of ATF to seals. Other types of lubricant will cause the transmission hydraulics to malfunction.



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Fig. 9: Extracting ATF From Torque Converter Using Oil Extractor V.A.G 1358 A And Oil Extractor Probe V.A.G 1358 A/1 Courtesy of VOLKSWAGEN UNITED STATES, INC.

If the ATF has become fouled by abrasion or when performing a major transmission overhaul, drain the torque converter as follows:

� Extract ATF from torque converter using oil extractor V.A.G1358A and oil extractor probe V.A.G1358A/1.

Torque converter oil seal, replacing


Fig. 10: Special Tool - Oil Seal Extractor Lever VW 681 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Extractor lever VW 681



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Fig. 11: Thrust Piece T10137 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Thrust piece T10137

Work procedure

� Remove transmission --> Transmission on vehicles with 6-cyl. GDI engine, removing.

� Mount transmission on assembly stand --> Securing transmission to assembly stand.

� Carefully pull out torque converter.

Fig. 12: Applying Extractor Lever VW 681 Directly Behind Sealing Lip Of Oil Seal Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove oil seal for torque converter using oil seal extractor VW681.

� Lightly lubricate outer circumference and sealing lips of oil seal with ATF.

� Installation position: open side of oil seal points toward transmission



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Fig. 13: Driving In Torque Converter Oil Seal With Thrust Piece T10137 Until Thrust Piece Reaches Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Drive in torque converter oil seal with thrust piece T10137 until thrust piece reaches stop.

Torque converter, checking

Fig. 14: Inspect Torque Converter Hub For Irregular Grooves Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Check hub - arrow - of torque converter for scoring.

Torque converter, installing


� Depth gauge

Installing

NOTE:� The torque converter is welded together and must be replaced as a

complete unit in the event of any damage or faults.



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� Press torque converter hub through oil seal as far as first stop.

� Lightly press torque converter inwards and turn until slots on torque converter hub engage in drive lugs on ATF pump gear and torque converter slides in a noticeable distance.

Fig. 15: Checking Torque Converter Is Correctly Positioned Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installation depth

If the torque converter is correctly installed, the depth between the contact surface of the tapped holes on the torque converter and the contact surface of the torque converter bell housing is at least 19 mm.

� Use new ribbed bolts to secure torque converter to drive plate.

When installing the transmission, adhere to the following instruction.

37 CONTROLS, HOUSING

ELECTRICAL/ELECTRONIC COMPONENTS AND LOCATIONS

CAUTION: If the torque converter is not installed correctly, the torque converter drive lugs or the ATF pump will be seriously damaged when the transmission is joined to the engine.

CAUTION: Before and while you are tightening the bolts on the engine/transmission flange keep checking that the torque converter can still be rotated behind the drive plate. If the converter cannot be turned, it must be assumed that it has not been installed correctly and the drive lugs on the converter or the ATF pump will be damaged when the bolts are fully tightened.



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Fig. 16: Connecting Data Link Connector (DLC) Courtesy of VOLKSWAGEN UNITED STATES, INC.

Data Link Connector (DLC)

Location: below knee padding on left side of steering wheel

The following components can be tested in the "Guided Fault Finding" using vehicle diagnostic, testing and information system VAS5051.

Fig. 17: Removing/Installing Securing Bolts For Mechatronics Unit In Sequence



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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mechatronics unit, Transmission Control Module (TCM) -J217- , Multi-function Transmission Range (TR) switch -F125- , Sensor for transmission RPM -G182- and Sender for transmission output RPM -G195-

Location: the mechatronics unit is bolted to the underside of the transmission housing and covered by the transmission oil pan.

The mechatronics unit incorporates the hydraulic control system, the electronic control module and the sensors and actuators as a complete synchronized unit. This includes:

� Transmission Control Module (TCM) J217

� Multi-Function Transmission Range (TR) Switch F125

� Sensor for transmission RPM G182

� Sender for transmission output RPM G195

The "mechatronics" unit can only be replaced as a complete unit.

� Removing and installing mechatronics unit --> Mechatronics unit , removing and installing.

Fig. 18: Locating Wiring Harness With Connector Is Attached To The Mechatronics Unit Courtesy of VOLKSWAGEN UNITED STATES, INC.

Internal wiring harness in transmission

NOTE:� All components mentioned are tested via Self- diagnosis.



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Location: the wiring harness - A - with connector - C - is attached to the mechatronics unit - B -.

� Removing and installing wiring harness --> Wiring harness in transmission, removing and installing.

Fig. 19: Transmission Range (TR) Selector Lever Display -Y6- Courtesy of VOLKSWAGEN UNITED STATES, INC.

Transmission Range (TR) Display Y6

Location: integrated into instrument cluster

Fig. 20: Kick Down Switch F8 Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:� The Transmission Range (TR) Display Y6 can only be replaced together

with instrument cluster.



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Kick Down Switch F8

Location: The Kick Down Switch F8 is located on the pedal cluster.

� Removing and installing Kick Down Switch F8 -->

� 20 - FUEL SUPPLY SYSTEM for 3.2 LITER V6 4V GENERIC SCAN TOOL, ENGINE CODE(S): BKH

� 20 - FUEL SUPPLY for 4.2 LITER V8 4V GENERIC SCAN TOOL, ENGINE CODE(S): BVJ

� 20 FUEL SUPPLY for 4.2 LITER V8 5V GENERIC SCAN TOOL, ENGINE CODE(S): BNK

� 20 - FUEL SUPPLY for 5.2 LITER 10-CYL. 4V GENERIC SCAN TOOL, ENGINE CODE(S): BXA

.

Fig. 21: Ttiptronic Switch F189 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Ttiptronic switch F189

Location: The tiptronic switch F189 is integrated in the printed circuit of the symbol panel, which is located in the selector mechanism cover - A -.

� Removing and installing tiptronic switch F189 --> Selector Lever Sensor System Control Module J587

NOTE:� The Kick Down Switch F8 is tested via Self- diagnosis.

NOTE:� The tiptronic switch F189 is tested via Self- diagnosis.



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and Tiptronic Switch F189 , removing and installing

SELECTOR MECHANISM, SERVICING

Selector mechanism, servicing

Ignition key removal lock, checking

� Turn ignition key to "ignition on" position.

� Press and hold brake pedal.

� When interlock button in selector lever handle is pressed, it should be possible to move selector lever out of position "P" without "catching".

� Switch off ignition.

� It should not be possible to remove the ignition key when the selector lever is in any position other than "P".

� Shift selector lever to position "P".

� Remove ignition key.

� It should only be possible to remove ignition key in selector lever position "P".

� Selector lever can then not be shifted out of "P" position with interlock button pressed and brake pedal depressed.

If the ignition key removal lock does not function as described, check Access/Start Authorization Switch E415 via "Guided Fault Finding" using vehicle diagnosis, testing and information system VAS 5051 A.

Selector mechanism, checking

� It should not be possible to operate the starter while the selector lever is in position "S" , "D" , "R" or in the "Tiptronic gate".

� When travelling at speeds above 5 km/h and shifting into selector lever position "N" , the solenoid for the selector lever lock must not engage and block the selector lever. The selector lever can be shifted into a driving gear.

� When travelling at speeds below 2 km/h (almost stationary) and shifting into selector lever position "N" , the solenoid for the selector lever lock should only engage after about 1 second. Selector lever cannot be shifted out of "N" position until brake pedal is depressed.

Selector lever in "P" position and ignition switched on:

CAUTION: Before working on vehicle when the engine is running, shift the selector lever into position "P" and apply the parking brake.



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� Do not depress brake pedal.

� Selector lever is locked and cannot be shifted out of "P" position. Shift Lock Solenoid N110 blocks selector lever.

� Press and hold brake pedal.

� Shift Lock Solenoid N110 releases selector lever. It is possible to shift into a driving gear. Shift selector lever slowly from "P" position through "R, N, D and S" and check whether the Transmission Range (TR) Display Y6 in the instrument cluster shows the correct selector lever position in each case.

Selector lever in "N" position and ignition switched on:

� Do not depress brake pedal.

� After a short waiting time: Selector lever is locked and cannot be shifted out of "N" position without pressing the interlock button on the selector lever handle. Shift Lock Solenoid N110 blocks selector lever.

� Depress brake pedal.

� Shift Lock Solenoid N110 releases selector lever. It is possible to shift into "D" position.

Selector lever in "D" position, ignition and lights switched on:

� Shift selector lever into "Tiptronic gate".

� The illuminated "D" symbol in the Selector Lever Transmission Range (TR) Position Display Y26 should go out and the "+" and "-" symbols should light up.

� The Transmission Range (TR) Display Y6 in the instrument cluster should change from "PRNDS" to "654321" when the selector lever is moved into the "Tiptronic gate".

If specifications are not attained:

� Adjust selector lever cable --> Selector lever cable, adjusting.

� Check ignition key removal lock --> Ignition key removal lock, checking.

Selector mechanism components, assembly overview



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Fig. 22: Selector Mechanism Components, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Securing clip

2 - Noise insulation

3 - Retaining clip

� Secures selector lever cable to selector housing

4 - Selector lever cable

� Do not bend or kink

� Removing and installing --> Selector lever cable, removing and installing � Selector lever cable must be replaced if rubber sleeve is damaged



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� Before installing, lightly lubricate ball socket with polycarbamide grease G052142 A2 .

� When installing, make sure that rubber sleeve (on transmission end) is not twisted

� Adjusting --> Selector lever cable, adjusting

5 - Clamping bolt, 13 Nm

6 - Pin for selector lever cable

� To remove selector lever cable pull plastic locking spring on selector mechanism forward slightly and push up pin just far enough to release cable.

7 - Shift Lock Solenoid N110

� Removing and installing --> Shift Lock Solenoid N110 , removing and installing

8 - Selector Lever Transmission Range (TR) Position Display Y26

� Removing and installing --> Selector Lever Transmission Range (TR) Position Display Y26 , removing and installing

9 - Clamp

� To secure selector lever handle to selector lever

� Removing and installing --> Selector lever handle, removing and installing

10 - Selector lever boot

� Detaching from selector lever handle --> Removing selector lever boot from selector lever handle

11 - Selector lever handle


12 - Trim ring

� Removing and installing --> Removing selector lever boot from selector lever handle

13 - 1.2 Nm

14 - Selector Lever Sensor System Control Module J587 and Tiptronic switch F189

� Removing and installing --> Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189 , removing and installing

15 - Transmission Park Selector Switch F305



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� Removing and installing --> Transmission Park Selector Switch F305 , removing and installing

16 - 10 Nm

17 - Selector housing

� Can only be renewed as a complete unit

� Removing and installing --> Selector mechanism, removing and installing

18 - Selector mechanism cover (bottom)

19 - 10 Nm

Selector lever handle components, Selector Lever Transmission Range (TR) Position Display Y26 , assembly overview

Fig. 23: Selector Lever Handle Components, Selector Lever Transmission Range Position Display Y26 ,



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Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Clamp

� To secure selector lever handle to selector lever


2 - Trim ring

� Removing and installing --> Removing selector lever boot from selector lever handle

3 - Selector lever handle


4 - Selector lever boot

� Removing from selector lever handle --> Removing selector lever boot from selector lever handle

5 - Selector Lever Transmission Range (TR) Position Display Y26

� Removing and installing --> Selector Lever Transmission Range (TR) Position Display Y26 , removing and installing

Operating manual selector mechanism release

Fig. 24: Prying Off Cover Cap In Ashtray Housing Using Screwdriver Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:� If the battery is disconnected or discharged, the selector lever cannot be

shifted from position "P". � When you operate the manual release mechanism the Shift Lock Solenoid

N110 will release the lock without current supply.



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� Remove insert for front ashtray.

� Use screwdriver to pry off cover cap in ashtray housing - arrow -.

Fig. 25: Pressing On Manual Release Lever Using A Screwdriver And Simultaneously Shift The Selector Lever Out Of Position Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Use a screwdriver or similar to press on manual release lever - arrow - and simultaneously shift the selector lever out of position "P".

Selector lever handle, removing and installing


Fig. 26: Identifying Hose Clamp Pliers V.A.G 1275 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Hose clamp pliers V.A.G 1275



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Fig. 27: Unclipping Mounting Frame For Selector Lever Boot From Center Console Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

� Shift selector lever to position "N".

� Unclip retaining frame for selector lever boot - 1 - from center console and lift off - arrows -.

Fig. 28: Securing The Interlock Button In Pulled-Out Position Using A Cable Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Use a cable tie to secure the interlock button in pulled-out position - arrow - , as shown in the illustration.

NOTE:� The selector lever handle is removed together with the selector lever boot.



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Fig. 29: Selector Lever Boot, Selector Lever Handle And Clamp Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Turn up selector lever boot - 1 - over selector lever handle - 2 -.

� Release clamp - arrow - and detach selector lever handle together with selector lever boot. Avoid touching the interlock button.

Fig. 30: Securing The Interlock Button In Pulled-Out Position Using A Cable Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing

NOTE:� To install the selector lever handle the interlock button has to be pulled

out to the stop and must be secured with either a cable tie - arrow - or with the assembly aid supplied together with the new handle.

� If, by mistake, the interlock button has not been secured, it must not be



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� Place selector lever handle fully on selector lever - interlock button points toward the driver.

� The handle must engage in selector lever annular groove.

� Remove cable tie or assembly aid, allowing the interlock button mechanism to engage in the vertical groove on the selector lever. If necessary, press the interlock button into the selector lever handle.

Fig. 31: Selector Lever Boot, Selector Lever Handle And Clamp Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Secure selector lever handle - 2 - onto selector lever with clamp - arrow -. Use hose clamp pliers V.A.G 1275 for this purpose.

� Clip retaining frame for selector lever boot - 1 - onto center console.

Removing selector lever boot from selector lever handle

pulled out of the selector lever handle using mechan ical tools. Apply a compressed air gun at the bottom of the handle and press the interlock button out with compressed air.



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Fig. 32: Removing Selector Lever Boot From Selector Lever Handle Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

� Remove selector lever handle --> Selector lever handle, removing and installing.

� Tie together selector lever handle spring tips - 1 - using cable tie - 3 - as shown in illustration.

� Slide sleeve - 2 - of selector lever boot past retainer tabs on spring tips - arrow -.

� Remove cable tie and detach sleeve with selector lever boot from selector lever.

Installing

Installation is carried out in reverse sequence. Note the following:

Installation position of selector lever boot:

� The longer side of the retaining frame for the selector lever boot faces drivers side.

� Install selector lever handle --> Selector lever handle, removing and installing.

Selector Lever Transmission Range (TR) Position Display Y26 , removing and installing



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Removing


� Unclip the retaining frame for selector lever boot - 1 - from center console and lift off - arrows -.

� Turn up selector lever boot.

Fig. 34: Releasing Retaining Spring And Removing Selector Lever Transmission Range (TR) Position Display Y26 Upward Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Release retaining spring - 2 - and detach Selector Lever Transmission Range (TR) Position Display Y26 - 1 - - arrow -.

� Disconnect electrical connector.



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Installing

Perform installation in reverse sequence of removal.

Selector mechanism components, assembly overview

Fig. 35: Selector Mechanism Components, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rubber sleeve for selector lever cable

� Check rubber sleeve for selector lever cable is correctly engaged on bottom cover of selector mechanism and make sure it seals properly.

NOTE:� Lubricate all bearings and moving surfaces with polycarbamide grease

G052142 A2 .



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2:34:16 AM





� When installing, make sure that the rubber sleeve (on transmission end) is not twisted



� To remove selector lever cable pull plastic locking spring on selector mechanism forwards slightly and push up pin just far enough to release cable.

4 - Shift Lock Solenoid N110

� Removing and installing --> Shift Lock Solenoid N110 , removing and installing

5 - Selector Lever Sensor System Control Module J587 and Tiptronic switch F189

� Removing and installing --> Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189 , removing and installing

6 - 1.2 Nm

7 - 10 Nm

8 - Selector housing

� Can only be replaced as a complete unit

� Removing and installing --> Selector mechanism, removing and installing

9 - Retaining clip


10 - Selector mechanism cover (bottom)

11 - 10 Nm

Shift Lock Solenoid N110 , removing and installing

Removing



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� Shift selector lever to position "S".

Fig. 36: Pulling Climatronic Control Module J255 (Control Head) Out Of Mounting Frame Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Grip Climatronic Control Module J255 at recesses on bottom (operating and display unit).

� Pull out Climatronic Control Module J255 (operating and display unit) from retaining frame - arrows -.

� Put Climatronic Control Module J255 (operating and display unit) on a cloth and place onto center console, to avoid damaging the surface.

Fig. 37: Disconnecting Electrical Harness Connectors In Sequence By Releasing Catches Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect electrical connectors in sequence - AD - by releasing the retainer tab - F -.

� Disconnect electrical connector - E -.



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Fig. 38: Removing Gap Cover Above Ashtray Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove trim cover above ashtray - arrow -.

Fig. 39: Housing For Front Ashtray And Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Open front ashtray.

� Remove insert for front ashtray.

� Remove bolts - 1 - and - 2 -.

� Remove housing for front ashtray - 3 - - arrow -.

� Disconnect electrical connector if installed.



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Fig. 40: Identifying Shift Lock Solenoid N110 Electrical Connector And Releasing Retainer And Pulling Out Shift Lock Solenoid N110 From The Front Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect electrical connector - 1 - from Shift Lock Solenoid N110.

� Release retainer - arrow A - and pull out Shift Lock Solenoid N110 from the front - arrow B -.

Installing

� Selector lever in position "S".

Fig. 41: Manual Release Lever Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Move manual release lever - arrow - upward.

NOTE:� For illustration purposes selector mechanism shown removed.

NOTE:� The operating lever - 1 - for Shift Lock Solenoid N110 moves into

installation position when the manual release lever is moved upward.



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Fig. 42: Placing Shift Lock Solenoid N110 Into Guide At An Angle From Above Courtesy of VOLKSWAGEN UNITED STATES, INC.

� At the same time place Shift Lock Solenoid N110 into guide at an angle from above.

Fig. 43: Placing Shift Lock Solenoid N110 Into Guide At An Angle From Above Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Press Shift Lock Solenoid N110 into guide until it engages.

� At the same time the ball head - 2 - of the Shift Lock Solenoid N110 should engage in the operating rod of the selector mechanism.

Perform remaining installation operations in reverse sequence of removal.

Tightening torque

Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189 , removing and installing

Component NmHousing for front ashtray to center console frame 3



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Removing

� Remove selector lever handle --> Selector lever handle, removing and installing.

� Remove front and rear sections of center console --> 68 - INTERIOR EQUIPMENT .

Fig. 44: Selector Lever Sensor System Control Module J587 With Tiptronic Switch F189 And Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect electrical connector - 1 -.

� Remove bolts - arrows - and remove Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189.

Installing


� Install front and rear sections of center console --> 68 - INTERIOR EQUIPMENT .

� Install selector lever handle --> Selector lever handle, removing and installing.

Tightening torque

Selector mechanism, removing and installing

Removing

NOTE:� Selector Lever Sensor System Control Module J587 and Tiptronic Switch

F189 are combined in one unit. � The magnets for the Tiptronic Switch F189 are secured on the cover.

Component NmSelector Lever Sensor System Control Module J587 and Tiptronic Switch F189 to selector housing1.2



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Fig. 45: Removing Rear Cross Member Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove rear cross piece - arrows -.

Fig. 46: Identifying Quick-Release Fasteners & Noise Insulation Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Unfasten quick-release catches - 2 - and detach rear noise insulation.



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Fig. 47: Removing Front Transverse Beam Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove front cross piece - arrows -.

� Remove drive shaft --> 39 FINAL DRIVE, REAR DIFFERENTIAL .

Fig. 48: Heat Shield Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Loosen inner side of covers on vehicle underside (left and right).

� Remove heat shield - arrow -.



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Fig. 49: Pressing Ball Socket Of Selector Lever Cable From Selector Shaft Lever & Removing Bracket On Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Mark installation position of support bracket for selector lever cable.

� Pry ball socket - 1 - of selector lever cable off selector shaft lever.

� Remove bolts - arrows - of support bracket for selector lever cable.

Fig. 50: Disconnecting Selector Mechanism Electrical Connectors And Removing Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove front and rear sections of center console --> 68 - INTERIOR EQUIPMENT .

� Disconnect electrical connectors - 2 - and - 4 -.

� Remove bolts - 1 - , - 3 - , - 5 - and - 6 -.

� Press retaining clips - arrows - inward and lower selector mechanism.

NOTE:� Do not bend or kink the selector lever cable.

NOTE:� The assistance of a second mechanic is required to detach the selector

mechanism from below.



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Installing


� Install support bracket for selector lever cable according to marking on the transmission.


� Install exhaust system so it is free of stress -->

� 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH

� 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK

� 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ

� 26 - EXHAUST SYSTEM, EMISSION CONTROLS 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA

.

� Install rear cross piece --> 40 - FRONT SUSPENSION .

� Install front cross piece --> 50 - BODY - FRONT .

� Install rear and front sections of center console --> 68 - INTERIOR EQUIPMENT .

� Check selector mechanism --> Selector mechanism, checking.

Tightening torque

Transmission Park Selector Switch F305 , removing and installing

The Transmission Park Selector Switch F305 consists of two microswitches. The two microswitches form the signal required by the electronic ignition key removal lock to release the key only in selector position P.

The first switch is closed when the Shift Lock Solenoid N110 is not actuated in selector position "P" , (brake pedal not depressed) and the manual release of the selector lever below the ashtray is not operated.

The second switch is closed when the button on the selector lever handle is not operated in selector position "P".

Note the following before replacing Transmission Park Selector Switch F305 :

NOTE:� Before installing, lightly lubricate ball socket on selector lever cable with

polycarbamide grease G052142 A2 . � Do not bend or kink the selector lever cable.

Component NmSupport bracket for selector lever cable to transmission 10Selector mechanism to body 10



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1. The two switches are connected in series, i.e. both switches must be closed before the ignition key can be removed. The switches can be checked with the vehicle diagnosis, testing and information system VAS 5051A in the Guided Fault Finding. After performing the vehicle system test, select the test program F305 - Gear selector position P switch (Powertrain / Automatic transmission 09L / 01 - systems capable of self-diagnosis / 02 - transmission electronics / electrical components).

2. It is possible to perform an electrical check on the switches. When performing a continuity test using a multimeter, note that the resistance is approx. 470 Ohm with both switches closed.

Removing

� Remove selector mechanism --> Selector mechanism, removing and installing

Fig. 51: Selector Lever Sensor System Control Module J587 With Tiptronic Switch F189 And Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - arrows - and remove Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189.



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Fig. 52: Removing/Installing Microswitch Off Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Release connector - D - and detach from Shift Lock Solenoid N110.

� Release connector - E - and disconnect by pulling it off upward.

� Press tab - C - in direction of - arrow 1 -.

� Remove microswitch - B - by pulling it off in direction of - arrow 2 -.

� Disengage electrical wire at selector mechanism - arrows A -.



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Fig. 53: Removing/Installing Selector Rod And Shift Selector Lever Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Unclip retaining clips - A - on both sides of selector mechanism.

� Press parking lock button - C - downward and hold.

� Pull selector rod - B - upward and shift selector lever in direction of - arrow - into selector lever position "S" onto stop.

Fig. 54: Removing/Installing Transmission Park Selector Switch F305 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Push locating pin - A - forward through rear opening for retaining clip in direction of - arrow - using a screwdriver

� Remove microswitch - B - toward front.

� Disengage electrical wire at lug - arrows C - and remove microswitch out of selector mechanism.

NOTE:� The locating pin - A - can remain installed; it is sufficient to press it

forward far enough for the microswitch - B - to be removed.



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Fig. 55: Removing/Installing Transmission Park Selector Switch F305 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing


� Take hold of the long electrical wire and guide microswitch into selector mechanism through opening below parking lock button.

� Install microswitch - B - into gearshift gate.

� Secure wire to lug - arrows C -. � Using a screwdriver, press in locating pin - A - as far as stop in opposite direction of arrow.

NOTE:� The microswitch must be seated flush.

NOTE:� The locating pin - A - locates the microswitch - B - in the gearshift gate. � If the microswitch is not correctly installed or not located properly, the

ignition key removal lock will not function as required.



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Fig. 56: Removing/Installing Microswitch Off Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Locate electrical wire - arrows A - on the selector mechanism as shown in the illustration.

� Install microswitch - B -.

� Connect connector - D - onto Shift Lock Solenoid N110.

� Clip in connector - E - from above.

NOTE:� If the microswitch is not correctly installed or not located properly, the

ignition key removal lock will not function as required.



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2:34:16 AM

Fig. 57: Removing/Installing Selector Rod And Shift Selector Lever Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Clip in retaining clips - A - on both sides of selector mechanism.

� Install Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189 --> Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189 , removing and installing

� Install selector mechanism --> Selector mechanism, removing and installing.

Selector lever cable, assembly overview



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Fig. 58: Selector Lever Cable, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Selector shaft lever

2 - Retaining clip

� Secures selector lever cable to support bracket







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� When installing, make sure that rubber sleeve (on transmission end) is not twisted


4 - Clamping bolt for selector lever cable, 13 Nm


� To remove selector lever cable pull plastic locking spring on selector mechanism forward slightly and push up pin just far enough to release cable.

6 - Retaining clip


7 - Rubber sleeve for selector lever cable

� Check that rubber sleeve for selector lever cable is correctly engaged on bottom cover of selector mechanism and make sure it seals properly.

8 - Bolt, 10 Nm

� Securing support bracket to transmission

9 - Support bracket for selector lever cable

Selector lever cable, removing and installing

Removing


Fig. 59: Removing Rear Cross Member Courtesy of VOLKSWAGEN UNITED STATES, INC.



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� Remove rear cross piece - arrows -.






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� Remove drive shaft --> 39 FINAL DRIVE, REAR DIFFERENTIAL .

Fig. 62: Heat Shield Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Loosen inner side of covers on vehicle underside (left and right).

� Remove heat shield - arrow -.


� Mark installation position of support bracket for selector lever cable.


� Remove support bracket bolts - arrows - for selector lever cable.



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Fig. 64: Identifying Lock Washers, Noise Insulation, Rubber Sleeve, Bottom Cover For Selector Mechanism And Nuts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Pry off lock washers - 1 -.

� Push noise insulation - 2 - forwards.

� Detach rubber sleeve - 3 - from bottom cover for selector mechanism - 4 -.

� Remove nuts - 5 -.

� Fold bottom cover for selector mechanism and noise insulation to front.

Fig. 65: Identifying Plastic Securing Spring, Pin, Screwdriver And Selector Lever Cable Courtesy of VOLKSWAGEN UNITED STATES, INC.




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� Remove retaining clip - 1 - for selector lever cable by pulling it off downward at the selector mechanism.

� Pull plastic securing spring - 2 - slightly forward and press pin - 3 - upward, but only as far as is necessary using a screwdriver.

� Pull selector lever cable - 4 - out of selector mechanism.

Installing


Fig. 66: Pushing Selector Lever Cable Into Selector Mechanism Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Push selector lever cable into selector mechanism and secure cable with retaining clip - 1 -.

� Installation position: angled end of retaining clip must point toward rear.

� Insert end of selector lever cable - 4 - into joint on selector lever.

� Push pin - 3 - down - arrow -. � Check plastic securing spring - 2 - has locked pin.

� Install support bracket for selector lever cable to new selector lever cable.

� Install support bracket for selector lever cable according to marking on transmission.


� Check selector mechanism --> Selector mechanism, checking.

� Install drive shaft --> 39 FINAL DRIVE, REAR DIFFERENTIAL

NOTE:� Make sure that pin is not pressed out completely.

NOTE:� Do not bend or kink the selector lever cable. � Before installing, lightly lubricate ball socket on selector lever cable with

polycarbamide grease G052142A2 .



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� Install exhaust system so it is free of stress -->





.

� Install rear cross piece --> 40 - FRONT SUSPENSION .

� Install front cross piece --> 50 - BODY - FRONT .

Tightening torques

Selector lever cable, adjusting


Fig. 67: Socket And Key T40031 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Socket and key T40031

Component NmSupport bracket for selector lever cable to transmission 10Bottom cover for selector mechanism to selector mechanism 10



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Procedure

� Unclip retaining frame for selector lever boot - 1 - from center console and lift off - arrows -.

Fig. 69: Shifting Selector Lever To Position "S" Courtesy of VOLKSWAGEN UNITED STATES, INC.


� Loosen clamping bolt for selector lever cable approx. 1 turn using socket and key T40031.

NOTE:� Clamping bolt can only be accessed with selector lever in position "S". � Loosen clamping bolt approx. 1 turn - do not remove.



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� Switch on ignition.

� Symbol "S" in the "PRNDS" display should be highlighted in the Transmission Range (TR) Display Y6 on the instrument cluster

If this is not the case:


� Loosen bolts - arrows - on support bracket for selector lever cable.

Fig. 71: Pushing Lever/Selector Shaft On Transmission Fully Forward Into Position "S" Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Adjust exact position "S" on transmission by slightly moving selector shaft lever - 2 -.



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� Tighten bolts - arrows - on support bracket for selector lever cable.

If symbol "S" in "PRNDS" display is highlighted in Transmission Range (TR) Display Y6 on instrument cluster:

Fig. 73: Shifting Selector Lever To Position "S" Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Carefully move selector lever slightly forward and backward, without shifting lever into a different selector lever position. The selector lever cable is thereby loosened.

� Tighten clamping bolt on selector lever cable - arrow - in this position.

Assemble in reverse sequence.

Tightening torque

NOTE:� When tightening the clamping bolt, the selector lever must not be pulled

forward or backward, as otherwise the setting will not be accurate.



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TRANSMISSION, REMOVING AND INSTALLING

Transmission, removing and installing

Overview:

� Removing transmission on vehicles with 6-cyl. GDI engine --> Transmission on vehicles with 6-cyl. GDI engine, removing

� Removing transmission on vehicles with 8-cyl. engine --> Transmission on vehicles with 8-cyl. engine, removing

� Installing transmission --> Transmission, installing

Transmission on vehicles with 6-cyl. GDI engine, removing

� Observe repair instructions --> Repair instructions.

Component NmClamping bolt for selector lever cable 13Support bracket for selector lever cable to transmission 10



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Fig. 74: Identifying Special Tools - Transmission On Vehicles With 6-Cyl. GDI Engine, Removing Courtesy of VOLKSWAGEN UNITED STATES, INC.


� Engine/transmission jack V.A.G1383 A

� Transmission support 3282

� Adjustment plate 3282/48

� Pin 3282/50

� Drip tray for workshop hoist VAS 6208

� Adapter T40058

� Bolt M10x20 (1x)

NOTE:� All cable ties which are released or cut open during removal must be



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� Activate jacking mode --> 43 - SELF LEVELING SUSPENSION .


Fig. 75: Disconnecting Ground (GND) Strap At Battery Ground (GND) Terminal Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove luggage compartment floor covering.

� Disconnect Ground (GND) wire - arrow - at battery.

installed in the same position when installing.

CAUTION: Prevent vehicle from tilting prior to removing the transmission. For this the luggage compartment must be empty.

CAUTION: Follow steps required when disconnecting battery --> 27 - STARTER, GENERATOR, CRUISE CONTROL .

NOTE:� When disconnecting the battery, the ignition key must remain in the

ignition lock so that wheels can be turned after the battery has been disconnected.

� On vehicles with all wheel drive the electronic parking brake must be released prior to disconnecting the battery so that the drive shaft can be turned for removal.



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� Release quick-release fasteners - 1 - and - 2 - and detach front and rear noise insulation.

Fig. 77: Noise Insulation In Wheel Housing (Left And Right) Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove noise insulation in wheel housing (left and right) - arrows -.



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2:34:16 AM

Fig. 78: Removing Heat Shield For Left Drive Axle Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove heat shield from transmission above left drive axle - arrows -.

� Remove left and right drive axles from transmission flanges.





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2:34:16 AM

Fig. 80: Loosening Clamping Sleeve Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect exhaust system at clamp - arrow -.

Fig. 81: Locating Bolts At Center Bracket For Front Exhaust Pipe Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - arrows - at center bracket for front exhaust pipe.

NOTE:� The flexible pipe connection (de-coupling element) on the front exhaust

pipe must not be bent more than 10 ° - otherwise it can be damaged.



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Fig. 82: Front Exhaust Pipe With Main Catalytic Converter And Nuts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove nuts - arrows - and remove front exhaust pipe with main catalytic converter.

Fig. 83: Tunnel Cross Member And Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - arrows - at tunnel cross member.

� Remove tunnel cross member with front exhaust pipe center bracket.



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2:34:17 AM

Fig. 84: Removing/Installing Heat Shield For Driveshaft Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove heat shield - A - for drive shaft - arrows -. � Remove bolts at transmission/drive shaft flange.

� Slide drive shaft together toward rear final drive. The constant velocity joints can be moved axially.

� Tie up drive shaft to body.

Fig. 85: Placing Torque Support On Rubber Buffer For Torque Support And Tightening Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Loosen bolts - arrows - at stop for torque reaction support.

� Press stop for torque reaction support upward and tighten bolts again.

CAUTION: During the following work steps the lock carrier must be installed in the normal position, and not moved to the service position.

NOTE:� Adjusting the stop for torque reaction support prevents the engine from

tilting at the front after the transmission is removed.



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Fig. 86: Transmission Support 3282 On Engine/Transmission Jack V.A.G 1383 A Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Set up transmission support 3282 on engine/transmission jack V.A.G 1383 A.

� Place adjustment plate 3282/48 on transmission support 3282 as shown in illustration.

� Align transmission support arms according to holes in adjustment plate.

� Attach support elements as illustrated on adjustment plate.

� Place engine/transmission jack V.A.G 1383 A with transmission support 3282 underneath transmission.

� Align adjustment plate 3282/48 parallel with transmission.

NOTE:� The stud 3282/50 is flattened at the side - arrow - , the flattened side

should face the oil pan when inserting stud into transmission.

NOTE:� The arrow symbol on the adjustment plate 3282/48 points in the direction

of travel.



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Fig. 87: Bolting Support To Left Rear Tapped Hole On Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Bolt support to rear left tapped hole on transmission - arrow1 - using one bolt (M10x20).

� Insert flattened stud 3282/50 into mounting hole at right rear of transmission housing - arrow 2 -.

Fig. 88: Inserting Pin Into Mounting Hole At Left Front Of Transmission Housing & Recess In Housing At Right Front Of Differential Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Insert stud into mounting hole at left front of transmission housing - arrow 2 -.

� Insert stud into recess in housing at right front of differential housing - arrow 1 -.

� Use engine/transmission jack V.A.G 1383 A to lift transmission up slightly.

CAUTION:� The flattened side of the stud 3282/50 must face towards the

transmission oil pan, to prevent the oil pan from being bent or damaged.

� Replace the transmission oil pan if damaged.



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Fig. 89: Removing Bolts For Left/Right Transmission Mount Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - arrows - for transmission mounting (left and right).

Fig. 90: ATF Lines Bracket On Top Section Of Oil Pan Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bracket - arrow - for ATF lines on top section of oil pan.

Fig. 91: Removing Bracket For ATF Lines At Bottom On Transmission



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� Remove bracket - arrow - for the ATF lines at the bottom section of transmission.

� Place drip tray for VAS 6100 VAS 6208 under transmission.

Fig. 92: Removing Bolt & Disconnecting ATF Lines From Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolt - arrow -.

� Detach ATF lines from transmission.

� Plug lines and openings at transmission with clean plugs.

Fig. 93: Bolts Removal Sequence Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:� Place a piece of cloth below connection points to catch escaping ATF.



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� Remove bolts - 1 - and - 2 - and lower subframe slightly at the rear.

Fig. 94: ATF Line Union Nuts And ATF Lines Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Mark position of ATF lines in relation to one another with a water-proof pen.

� Loosen both ATF line union nuts - arrows - and disconnect ATF lines.

� Plug open ends of lines with clean plugs.

� Remove ATF lines from between subframe and transmission.

Fig. 95: Starter Mounting Bolts And Connectors Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect wires - 2 - and - 3 - at starter.

� Remove starter --> 27 - STARTER, GENERATOR, CRUISE CONTROL



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2:34:17 AM

Fig. 96: Inserting Guide Pin Of Adapter T40058 So That Large Diameter Points To Engine Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Insert adapter T40058 guide pin so that the large diameter - arrow 1 - faces engine. The smaller diameter - arrow 2 - faces adapter.

Fig. 97: Loosening Torque Converter Bolts Using Adapter T40058 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Counter-hold crankshaft using adapter T40058 to loosen torque converter bolts.

NOTE:� - Arrow - can be disregarded.



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2:34:17 AM

Fig. 98: Torque Converter Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove 3 Torx socket head bolts - arrows - of the torque converter through the opening for the removed starter (turning the crankshaft 1 / 3 turn each time).

Fig. 99: Disconnecting Transmission Control Module (TCM) J217 Electrical Harness Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect electrical connector at transmission by turning fastener cap counter-clockwise - arrow -.

� Move all electrical wiring clear of transmission housing.



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2:34:17 AM

Fig. 100: Left Transmission Support, Bolts And Transmission Mounting - Vehicles With 6-Cyl. GDI Engine Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - 4 - , - 5 - and - 9 - and remove left transmission support with transmission mounting.

Fig. 101: Right Transmission Support, Bolts And Transmission Mounting Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - 4 - , - 8 - and - 9 - and remove right transmission support with transmission mounting.



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� Remove support bracket from transmission - arrows -.

� Move clear selector lever cable.

� Lower transmission slightly at rear using engine/transmission jack V.A.G 1383 A.

Fig. 103: Location Of Engine Speed (RPM) Sensor G28 On Coupling Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove Engine Speed (RPM) Sensor G28 on transmission - arrow -.

NOTE:� Mark support bracket installation position for selector lever cable with a

felt-tip pen.



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2:34:17 AM

Fig. 104: Removing Bolts Uniformly At Left/Right Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - arrows - on left and right evenly.

� Remove stabilizer bar.

Fig. 105: Identifying Engine/Transmission Threaded Connections Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - 3...10 - from engine/transmission flange.



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2:34:17 AM

Fig. 106: Using Assembly Lever To Press Torque Converter Off Drive Plate Of Engine Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Using a tire iron or other suitable lever, pry torque converter away from engine drive plate - arrow -.

� Press transmission off dowel sleeves and lower it carefully.

Fig. 107: Lowering Rear Edge Of Transmission By Adjusting Transmission Support 3282 Accordingly Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Lower rear edge of the transmission by adjusting the transmission support 3282 accordingly.

� Guide transmission out diagonally downward/to the rear.

Transmission on vehicles with 8-cyl. engine, removing

� Observe repair instructions --> Repair instructions.

CAUTION:� When lowering transmission, make sure there is sufficient clearance

to axle shafts. � Secure the torque converter to prevent it from falling out.

NOTE:� All cable ties which are released or cut open during removal must be

installed in the same position when installing.



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2:34:17 AM

� The transmission is removed with the engine, then the two components are separated.

� Removing and installing engine -->

� 10 - ENGINE - ASSEMBLY for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK

� 10 - ENGINE - ASSEMBLY for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ

� 10 - ENGINE - ASSEMBLY for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BAT, BNK

Transmission, installing


Fig. 108: Checking Torque Converter Is Correctly Positioned Courtesy of VOLKSWAGEN UNITED STATES, INC.

CAUTION: Prevent vehicle from tilting prior to removing the transmission. For this the luggage compartment must be empty.

NOTE:� Clean ATF lines and ATF cooler before installing exchange transmission --

> ATF lines and ATF cooler, cleaning . � Replace self-locking nuts and bolts when performing assembly work. � Replace oil seals and gaskets, and bolts which are tightened by turning

through a specified angle. � Re-attach heat shield sleeves at the same locations when re-installing. � Hose connections and hoses for charge air system must be free from oil

and grease before installing. � Secure all hose connections with the correct hose clips (as original

equipment). � Re-attach all cable ties at the same locations when re-installing.



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2:34:17 AM

� Before installing transmission, you must make sure that the torque converter is properly installed in the transmission.

� If the torque converter is correctly installed, the depth between the contact faces at the tapped holes on the torque converter and the contact surface of the torque converter bell housing is approx. 19mm.


� Before installing transmission, check for correct positioning of dowel sleeves - A - at cylinder block. Install new dowel sleeves if necessary.

� If an intermediate plate was installed between engine and transmission, reinstall plate in same position.

� Before joining engine and transmission, turn torque converter and drive plate (on engine) until one hole and one tapped hole are in line with the opening for the removed starter.

� When pushing the engine and transmission together, ensure that no cables, lines, etc. can become trapped.

When you then install the transmission, adhere to the following instructions.

CAUTION: If the torque converter is not installed correctly, the torque converter drive lugs or the ATF pump will be seriously damaged when the transmission is joined to the engine.

CAUTION:� Before and while you are tightening the bolts on the

engine/transmission flange keep checking that the torque converter can still be rotated behind the drive plate.

� If the converter cannot be turned, it must be assumed that it has not been installed correctly and the drive lugs on the converter or the ATF pump will be damaged when the bolts are fully tightened.



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2:34:17 AM


� Bolt transmission onto engine.

Fig. 111: Inserting Guide Pin Of Adapter T40058 So That Large Diameter Points To Engine Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Insert adapter T40058 guide pin so that the large diameter - arrow 1 - faces engine. The smaller diameter - arrow 2 - faces adapter.

NOTE:� Tightening torques only apply to lightly greased, oiled, phosphated or

blackened nuts and bolts. � Additional lubricant such as engine or gear oil may be used, but do not

use graphite lubricant. � Do not use parts which have been degreased. � Tolerance for tightening torques ± 15%.



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2:34:17 AM

Fig. 112: Loosening Torque Converter Bolts Using Adapter T40058 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Counter-hold crankshaft using adapter T40058 to secure torque converter bolts.

� Use new ribbed bolts to secure torque converter to drive plate.

Fig. 113: Torque Converter Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Screw in 3bolts - arrow - for torque converter hand-tight through opening of removed starter (turning crankshaft 1 / 3 turn each time).

� Tighten torque converter bolts to torque (turning crankshaft 1 / 3 turn each time).

� Install starter --> 27 - STARTER, GENERATOR, CRUISE CONTROL .

NOTE:� - Arrow - can be disregarded.



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2:34:17 AM

Fig. 114: Placing Torque Support On Rubber Buffer For Torque Support And Tightening Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Loosen bolts - arrows - for torque reaction support.

� Allow stop for torque reaction support to settle on rubber buffer for torque reaction support and re-tighten bolts.


On vehicles with 6-cyl. GDI engine:

� Install transmission supports and transmission mountings.



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2:34:17 AM

Fig. 116: Left Transmission Support, Bolts And Transmission Mounting - Vehicles With 8-Cyl. Engine Courtesy of VOLKSWAGEN UNITED STATES, INC.

On vehicles with 8-cyl. engine:

� Install transmission support, transmission mounting and tunnel cross member.

All models:

� Secure drive shaft to transmission --> 39 FINAL DRIVE, REAR DIFFERENTIAL .

� Bolt drive axles to flange shafts --> 40 - FRONT SUSPENSION .

� Electrical connections and routing Electrical Wiring Diagrams, Troubleshooting Component Locations

� Check selector lever cable adjustment --> Selector lever cable, adjusting.

� Check oil level in final drive (front) --> Front final drive gear oil. � Check oil level in transfer gear --> Transfer gear oil level. � Install exhaust system free of stress -->





.

� Follow steps required after connecting battery --> 27 - STARTER, GENERATOR, CRUISE CONTROL .

NOTE:� When replacing transmission, take off transmission support from

transmission to be exchanged and install to replacement transmission



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2:34:17 AM

� Fill cooling system -->

� 19 - ENGINE - COOLING SYSTEM for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH

� 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK

� 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ

� 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BAT, BNK

� 19 - ENGINE - COOLING SYSTEM for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA

.

� Check ATF level in planetary gearbox --> ATF level, checking and correcting.

� Deactivate jacking mode --> 43 - SELF LEVELING SUSPENSION .

Tightening torques


Component NmBracket for exhaust pipe lug. 23Heat shields above drive axles to transmission 23Heat shield for drive shaft to transmission cover 25Bracket for noise insulation to subframe 10Support bracket to transmission 10Torque converter to drive plate; always replace bolts 85



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2:34:17 AM

Securing engine/transmission assembly on vehicles with 6-cyl. GDI engine:

*Bolt strength 10.9


Securing engine/transmission assembly on vehicles with 8-cyl. engine:

*Bolt strength 10.9

Automatic transmission, transporting


Item Bolt Nm1 M10x80 65 * See note2 M10x90 65 * See note

3, 4,5 M12x95 656, 7 M12x115 65

8, 9, 10 M10x80 45A Dowel sleeves for centering

Item Bolt Nm1 M10x80 65 * See note2 M12x90 65 * See note3 M12x105 65

4, 5 M12x100 656 M12x125 657 M12x170 65

8, 9, 10 M10x60 45A Dowel sleeves for centering



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Fig. 119: Identifying Special Tools - Automatic Transmission, Transporting Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Attachment and holding rig 3457

Fig. 120: Special Tool 3457 Attachment To Transmission Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

Attachment and holding rig 3457 can be used to transport the automatic gearbox and also when setting up transmission support 3282.

� Install attachment and holding rig 3457 to attachment points on transmission housing and secure in place.

Securing transmission to assembly stand



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Fig. 121: Identifying Special Tools -- Transmission, Securing To Assembly Stand Courtesy of VOLKSWAGEN UNITED STATES, INC.


� Attachment and holding rig 3457

� Support clamp VW313

� Support plate VW309

� Workshop crane V.A.G1202A

Procedure

� Remove transmission --> Transmission on vehicles with 6-cyl. GDI engine, removing.



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Fig. 122: Special Tool 3457 Attachment To Transmission Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Install attachment and holding rig 3457 to attachment points on transmission housing and secure in place.

� Bolt transportation tool onto support plate VW309 and install into support clamp VW313 with the aid of workshop crane.

Transmission mounting, removing and installing

Removing and installing transmission mounting, transmission support and tunnel cross member on vehicles with 6-cyl. GDI and 8-cyl. engine


Fig. 123: Identifying Engine/Transmission Jack V.A.G. 1383 A

CAUTION: The center of gravity of the transmission is outside the pivot center of the support clamp. A second mechanic has to hold the transmission housing when it is being turned to prevent it from swinging round.

NOTE:� If the filled transmission with oil pan is to be turned upside down on

assembly stand, the transmission housing and final drive breathers must be sealed.



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2:34:17 AM


� Engine/transmission jack V.A.G 1383 A

� Block of wood

Fig. 124: Transmission Mounting And Transmission Support Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing transmission mounting - 2 - and transmission support - 4 -



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� Release quick-release fasteners - 1 - and - 2 - and detach noise insulation panels.

Fig. 126: Removing/Installing Mounting Bolts For Front Exhaust Pipes Courtesy of VOLKSWAGEN UNITED STATES, INC.



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2:34:17 AM

� Remove bolts - 13 - and remove rear bracket for front exhaust pipe.

� Apply lifting column of engine/transmission jack V.A.G 1383 A at transfer gear behind tunnel cross member (place a block of wood between lifting column and transfer gear).


Fig. 127: Removing Bolts On Tunnel Cross Member Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - arrows - for tunnel cross member.

Fig. 128: Tunnel Cross-Member And Nuts

CAUTION:� Do not apply the lifting column with the block of wood under the

transmission oil pan. � When a load is applied to the oil pan it is damaged and has to be

replaced.



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� Remove bolts - 1 - and - 2 - and move tunnel cross member slightly towards rear.


� Remove transmission mounting - 2 - between transmission and tunnel cross member.

� Remove bolts - 3 - and detach transmission support - 4 - from transmission.

Installing transmission mounting - 2 - and transmission support - 4 -

Perform installation in reverse sequence of removal.

� Install transmission support - 4 -.

� Install transmission mounting - 2 -.

� Install tunnel cross member - 2 - Removing tunnel cross-member under Removing and installing transmission mounting, transmission support and tunnel cross member on vehicles with 6-cyl. GDI and 8-cyl. engine

� Install exhaust system free of stress -->




� 26 - EXHAUST SYSTEM, EMISSION CONTROLS 5.2 LITER 10-CYL. 4V ENGINE



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MECHANICAL ENGINE CODE(S): BXA

.

� Deactivate jacking mode --> 43 - SELF LEVELING SUSPENSION


Tightening torques

Component NmTransmission support to transmission - 3 - 23Transmission mounting to transmission support - 1 - 23



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Fig. 131: Tunnel Cross-Member Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing tunnel cross-member - 1 -



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� Activate jacking mode --> Running gear, front-wheel drive and four-wheel drive 43 - SELF LEVELING SUSPENSION .


Fig. 133: Removing/Installing Mounting Bolts For Front Exhaust Pipes Courtesy of VOLKSWAGEN UNITED STATES, INC.



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� Remove bolts - 13 - and remove rear bracket for front exhaust pipe.

Fig. 134: Loosening Clamping Sleeves Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Loosen clamps - 1 - and - 2 -.

� Remove front exhaust pipe with catalytic converter (left-side) -->





.

� Tie up front exhaust pipe (right) to the side or support from below.

CAUTION: To prevent damage, the flexible joints in the front exhaust pipe must not be bent more than 10 °.



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2:34:17 AM


� Remove front cross member - arrows -.

� Apply lifting column of engine/transmission jack V.A.G 1383 A at transfer gear behind tunnel cross member (place a block of wood between lifting column and transfer gear).


Fig. 136: Removing Bolts On Tunnel Cross Member Courtesy of VOLKSWAGEN UNITED STATES, INC.

CAUTION:� Do not apply the lifting column with the block of wood under the oil

pan. � When a load is applied to the oil pan it is damaged and has to be

replaced.



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2:34:17 AM

� Remove bolts - arrows - for tunnel cross member.

Fig. 137: Tunnel Cross-Member And Nuts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove nuts - 1 -.

� Remove tunnel cross member.

Installing tunnel cross-member - 1 -



Tightening torques



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2:34:17 AM






.


Removing and installing transmission support and transmission mounting (right and left) on vehicles with 6-cyl. GDI engine


Fig. 139: Identifying Engine/Transmission Jack V.A.G. 1383 A Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Engine/transmission jack V.A.G 1383 A

Component NmTransmission mounting to tunnel cross member - 3 - 23Tunnel cross member to body - 2 - 40



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Removing





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Fig. 141: Removing Subframe Transverse Beam Courtesy of VOLKSWAGEN UNITED STATES, INC.


Fig. 142: Placing Lifting Surface Of Engine/Transmission Jack V.A.G 1383 A Centrally On Lower Housing Base Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Detach universal mounting bracket V.A.G 1359/2 from engine/transmission jack V.A.G 1383 A.

� Place telescopic column of engine/transmission jack V.A.G 1383 A centered below cast lug on transmission housing - arrow - and raise transmission slightly.

Transmission support and transmission mounting (left-side) on vehicles with 6-cyl. GDI engine:

� Remove front exhaust pipe with catalytic converter (left side) -->




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2:34:17 AM




.


� Remove bolts - 1 -.

� Remove bolts - 4 - , - 5 - and - 9 - and remove left transmission support with transmission mounting.

Transmission support and transmission mounting (right-side) on vehicles with 6-cyl. GDI engine:



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2:34:17 AM


� Remove bolts - 1 -.

� Remove bolts - 4 - , - 8 - and - 9 - and remove right transmission support with transmission mounting.

Installing







.




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2:34:18 AM


Tightening torques of transmission mounting (right-side) on vehicles with 6-cyl. GDI engine

1. 23 Nm

2. Subframe

3. Transmission mounting (right-side)

4. 23 Nm

5. Transmission support (right-side)

6. Washer

7. 40 Nm

8. 23 Nm

9. 23 Nm



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Tightening torques of transmission mounting (left-side) on vehicles with 6-cyl. GDI engine

1. 23 Nm

2. Subframe

3. Transmission mounting (left-side)

4. 23 Nm

5. 23 Nm

6. 40 Nm

7. Washer

8. Transmission support (left-side)

9. 23 Nm

ATF LEVEL IN PLANETARY GEARBOX

ATF level in planetary gearbox

ATF level, checking and correcting


rules .



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Fig. 147: Identifying Special Tools - ATF Level, Checking And Correcting Courtesy of VOLKSWAGEN UNITED STATES, INC.


� Vehicle diagnostic, testing and information system VAS5051


� ATF charging device V.A.G 1924

� Safety goggles

Test conditions

� Transmission must not be in emergency running (backup) mode.

� Vehicle must be level (horizontal).

� Selector lever in position "P" , engine idling.



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� Air conditioner and heating system switched off.

� Vehicle diagnostic, testing and information system VAS5051 connected up; vehicle self-diagnosis and vehicle system "02 - Gearbox electronics" selected.

� The ATF temperature at the beginning of the test must not be higher than 30 ° C. If necessary, first allow the transmission to cool down.

Fig. 148: Diagnostic System VAS 5051: Display -- Basic Setting Courtesy of VOLKSWAGEN UNITED STATES, INC.

ATF temperature reading

Display on VAS5051 :

� From list - 1 - select diagnostic function "08 - Read data block (measured value block)".

NOTE:� The ATF temperature is taken from the reading on the vehicle diagnostic,

testing and information system VAS5051. � The ATF level will vary according to the ATF temperature. � If the ATF level is checked when the ATF temperature is too low, this will

result in overfilling. � If the level is checked when the ATF temperature is too high, this will

result in underfilling. � Both overfilling and underfilling have a detrimental effect on the

functioning of the transmission � Use only the correct type of ATF (available as a replacement part) for the

planetary gearing in automatic transmission 09L. Other oils cause malfunctions and/or failure of the transmission.



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Fig. 149: Diagnostic System VAS 5051: Display - Display Group And Key Pad Courtesy of VOLKSWAGEN UNITED STATES, INC.


1 - Enter display group

� Use keypad - 2 - to enter "4" for "Display group number 4" and confirm by touching Q key.

Fig. 150: Diagnostic System VAS 5051: Display Courtesy of VOLKSWAGEN UNITED STATES, INC.


� Reading for ATF temperature is shown in display zone - 1 -.

Checking and correcting ATF level

NOTE:� The ATF level is checked at the ATF inspection plug. � At an ATF temperature between 35 ° and 45 ° C (50 ° C for tropical

countries) a small amount of fluid should drain out of the inspection bore if the transmission is filled with the proper quantity of ATF (this is normal as the fluid expands as it heats up).



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� Drive vehicle onto a four-column lifting platform or over an inspection pit in order for it to be absolutely horizontal.

� Fill container of ATF charging device V.A.G 1924 with ATF for automatic transmission 09L.

Fig. 151: Securing Container Of ATF Filler Tool VAG1924 As High Up On Vehicle As Possible Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Secure container for ATF charging device V.A.G 1924 as high as possible on vehicle.

� Start engine and let it idle.

� Place drip tray for workshop hoist VAS 6208 under transmission.

NOTE:� Before raising the vehicle on a lifting platform (wheels off the ground) you

must first activate the jacking mode --> 43 - SELF LEVELING SUSPENSION .

CAUTION: The ATF charging device must be clean and the ATF must not be mixed with other types of ATF!

CAUTION: Wear safety goggles.



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Fig. 152: Identifying ATF Inspection Plug Courtesy of VOLKSWAGEN UNITED STATES, INC.

� When an ATF temperature of 35 ° C is reached, remove ATF inspection plug - arrow B - and drain off any surplus ATF.

Fig. 153: Filler Plug Seal Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Replace ATF inspection plug seal - arrow -.

Fig. 154: Correct ATF Level



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If ATF emerges from the inspection opening before the ATF has reached 40 ° C the ATF level is OK - arrow -.

If still no ATF emerges from ATF inspection opening when ATF has reached 45 ° C, top off with ATF.

� Install new seal on ATF inspection plug and tighten to 80 Nm. The ATF check is now completed.

� End function "08 - Read data block (measured value block)" by touching <-- key.

� Press "06 - End output".

� Switch off ignition and disconnect diagnostic connector.

Filling up ATF

If still no ATF emerges from ATF inspection opening when ATF has reached 40 ° C, top off with ATF.

Fig. 155: Fill With ATF Using V.A.G 1924 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Guide ATF charging device V.A.G 1924 filler nozzle in from below through an opening in the deflector cap - arrow - , taking care not to push deflector cap upward out of position.

� Fill with ATF using ATF charging device V.A.G 1924 until ATF comes out of inspection hole.

NOTE:� The ATF inspection plug must be screwed in again at the latest when ATF

reaches a temperature of 45 ° C (countries with hot climates: 50 ° C).

NOTE:� If the vehicle has been raised on a lifting platform you must also de-

activate the jacking mode --> 43 - SELF LEVELING SUSPENSION .

NOTE:� The ATF inspection plug must be screwed in again at the latest when

temperature reaches 45 ° C (hot climates: 50 ° C). If necessary, switch off engine, allow gearbox to cool down and repeat the test.



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� Install new seal on ATF inspection plug and tighten to 80 Nm.

� End function "08 - Read data block (measured value block)" by touching <-- key.

� Press "06 - End output".

� Switch off ignition and disconnect diagnostic connector.

Draining ATF or filling up after performing repairs


Fig. 156: Drip Tray For VAS 6100, VAS 6208 Courtesy of VOLKSWAGEN UNITED STATES, INC.


Fig. 157: V.A.G 1924 Reservoir Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:� The ATF level must not be too low or too high, otherwise this would impair

the function of the transmission.





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2:34:18 AM

� ATF charging device V.A.G 1924

� Safety goggles

Procedure

� Engine not running.

� Drive vehicle onto a lifting platform or over an inspection pit in order for it to be absolutely horizontal.

� Fill container of ATF charging device V.A.G 1924 with ATF for automatic transmission 09L

Fig. 158: Securing Container Of ATF Filler Tool VAG1924 As High Up On Vehicle As Possible Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Secure container for ATF charging device V.A.G 1924 as high as possible on vehicle.


must first activate the jacking mode --> 43 - SELF LEVELING SUSPENSION .

CAUTION:� The ATF charging device must be clean and the ATF must not be

mixed with other types of ATF! � The transmission is destroyed if ATF is mixed with other types of

ATF.

CAUTION:



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2:34:18 AM




Draining ATF



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2:34:18 AM


� Remove ATF drain plug - arrow A -. � Drain ATF.

� Tighten new drain plug - arrow A - to 12 Nm.

Filling transmission with ATF

� Remove ATF inspection plug - arrow B -.

Fig. 161: Fill With ATF Using V.A.G 1924 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Guide ATF charging device V.A.G 1924 filler nozzle in from below through an opening in deflector cap - arrow - , taking care not to push deflector cap upward out of position.

� Fill with ATF using ATF charging device V.A.G 1924 until ATF comes out of inspection hole.


� Start engine.

NOTE:� Observe relevant disposal regulations. � The engine must not be started and vehicle must not be towed without

ATF in transmission. � The drain plug with seal must be replaced.

CAUTION: Allow engine to idle for approx. 20 seconds and then turn off.

NOTE:� This process of starting the engine for a short period of time and then

turning it off is required to ensure that the ATF pump does not draw in air. This prevents the building up of foam in the ATF, which would result in an inaccurate reading of the ATF level.



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� Continue filling with ATF using ATF charging device V.A.G 1924 until ATF comes out of inspection hole again.

� Start engine and allow to idle.

� With the engine idling, continue filling with ATF using ATF charging device V.A.G 1924 until ATF comes out of inspection hole again.

� Tighten ATF inspection plug.

� With engine idling, press brake pedal and shift selector lever through all selector lever positions leaving selector lever at least 10seconds in each position.


� Increase engine speed to 2000 rpm and maintain for at least 60 seconds.


� Check ATF level --> ATF level, checking and correcting.

ATF LINES

ATF lines

ATF lines and ATF cooler, assembly overview

NOTE:� Observe all notes and test requirements for "Checking and correcting ATF

level".

NOTE:� General repair instructions --> General repair instructions .


rules . � Thoroughly clean all joints and surrounding areas before disassembling. � Check ATF level after replacing ATF lines/hoses or ATF cooler --> ATF

level, checking and correcting .

CAUTION:� Drain cooling system completely before removing and installing ATF

cooler --> � 19 - ENGINE - COOLING SYSTEM for 3.2 V6 4V ENGINE

MECHANICAL, ENGINE CODE(S): BKH � 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE

MECHANICAL, ENGINE CODE(S): BAT, BNK � 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE

MECHANICAL, ENGINE CODE(S): BVJ � 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V FUEL



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ATF lines and ATF cooler - assembly overview for vehicles with 6-cyl. GDI engine

ATF lines and ATF cooler - assembly overview for vehicles with 8-cyl. engine

ATF lines and ATF cooler for vehicles with 6-cyl. GDI engine, assembly overview

INJECTION AND IGNITION, ENGINE CODE(S): BAT, BNK � 19 - ENGINE - COOLING SYSTEM for 5.2 LITER 10-CYL. 4V

ENGINE MECHANICAL ENGINE CODE(S): BXA .

� Always use cooling system charge unit VAS6096 when refilling cooling system -->

� 19 - ENGINE - COOLING SYSTEM for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH

� 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK

� 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ

� 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BAT, BNK

� 19 - ENGINE - COOLING SYSTEM for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA

. Otherwise there is a danger of malfunction.



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Fig. 162: ATF Lines And ATF Cooler For Vehicles With 6-Cyl. GDI Engine, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - O-rings

� Always replace

� Lubricate with ATF when installing

2 - Bolt, 21 Nm

� Do not tighten until lines have been fully inserted

3 - ATF line

� Note correct location

� Push ATF lines fully into transmission by hand as far as stop, then bolt on.



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2:34:18 AM

4 - ATF line


� Push ATF lines fully into transmission by hand as far as stop, then bolt on.

5 - Bracket for ATF line

6 - Bolt, 5 Nm

7 - Bolt

� 3 Nm, all other 6-cyl. engines except for 6-cyl. 3.2 ltr. 4V engine (direct injection)

� 10 Nm, only on vehicles with 6-cyl. 3.2 ltr. 4V engine (direct injection)

8 - Bracket

9 - ATF line


10 - ATF line


11 - ATF cooler

� Clean ATF cooler --> ATF lines and ATF cooler, cleaning.

12 - ATF line


� Push ATF lines fully into cooler by hand as far as stop, then bolt on

13 - Bracket

14 - ATF line



15 - Bolt, 5 Nm

16 - Bolt, 5 Nm

17 - Nut, 5 Nm



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19 - Bolt, 5 Nm

20 - Bracket

Fig. 163: ATF Line Union Nuts And ATF Lines Courtesy of VOLKSWAGEN UNITED STATES, INC.

Union nut - arrows - , 29 Nm

� For connecting ATF lines

� Note location of ATF lines

ATF lines and ATF cooler for vehicles with 8-cyl. engine, assembly overview



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Fig. 164: ATF Lines And ATF Cooler For Vehicles With 8-Cyl. Engine, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - O-rings

� Always replace

� Lubricate with ATF when installing

2 - Bolt, 21 Nm


3 - ATF line


� Push ATF lines fully into gearbox by hand as far as stop, then bolt on.



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4 - ATF line


� Push ATF lines fully into gearbox by hand as far as stop, then bolt on.


6 - Nut, 5 Nm

7 - ATF cooler

� Clean ATF cooler --> ATF lines and ATF cooler, cleaning.

8 - ATF line



9 - ATF line



10 - Bolt, 5 Nm


11 - Bolt, 5 Nm


12 - Center hex stud, 7 Nm

13 - Bracket

14 - Union nut, 29 Nm

For connecting ATF lines

Note location of ATF lines

ATF cooling lines, removing and installing




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� Drip tray

� Safety goggles

Removing

� Mark position of all ATF cooling lines in relation to one another with different colors to avoid confusion.

� Place drip tray for workshop hoist VAS 6208 underneath.

� Disconnect ATF cooling lines.

� Seal opened cooling lines with clean sealing plugs.

Installing


� Clean ATF cooling lines --> ATF lines and ATF cooler, cleaning.

� Lightly lubricate O-rings with ATF.

� First push ATF cooling lines fully into transmission or cooler as far as stop, then bolt on --> ATF lines and ATF cooler, assembly overview.


ATF lines and ATF cooler, cleaning

NOTE:� Read the rules when working on the automatic transmission. � Thoroughly clean all joints and surrounding areas before disassembling.




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� Compressed air gun (commercially available)

� Hose, approx. 18mm dia.

� Drip tray

Fig. 166: Location Of ATF Lines At Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC.

Procedure

� Place drip tray underneath.

� Remove bolt - 2 -.

� Connect a hose (approx. 18mmdiameter) to ATF line - A - and secure with a hose clip. Place the other end of the hose into drip tray.

� Blow through ATF line - B - using a compressed air line (max. 10 bar).

� Change hose from ATF line - A - over to ATF line - B - and repeat sequence.

� In addition, flush lines with ATF until they are clean if ATF is very dirty.

� The ATF used for flushing the lines must not be used again.

� Always replace O-rings - 1 -.

� First push ATF cooling lines fully into transmission or cooler as far as stop, then bolt on --> ATF lines

NOTE:� Always clean ATF cooling lines and ATF cooler before installing a

replacement transmission. � Read the rules when working on the automatic transmission. � Thoroughly clean all joints and surrounding areas before disassembling.




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and ATF cooler, assembly overview.


38 GEARS, CONTROL

OIL PAN, ATF STRAINER AND MECHATRONICS UNIT, REMOVING AND INSTALLING

Oil pan, ATF strainer and mechatronics unit, removing and installing

Oil pan, removing and installing




� Safety goggles

Removing

CAUTION: Do not run engine or tow vehicle with oil pan removed or when there is no ATF in the transmission.

NOTE:� General repair instructions --> General repair instructions . � Read the Read the rules when working on the automatic transmission -->

Read the rules . � Always replace mechatronics unit if contaminated or faulty. � Lightly lubricate O-rings and seals with ATF. Other types of lubricant will

cause the transmission hydraulics to malfunction.

NOTE:� General repair instructions --> General repair instructions .



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� Read the rules when working on the automatic transmission --> Read the rules .



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Fig. 169: Removing Subframe Transverse Beam Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove front cross piece beneath transmission oil pan - arrows -.

� Place drip tray for workshop hoist VAS 6208 under the transmission.


� Remove ATF drain plug - arrow A -. � Drain ATF.

NOTE:� - Item 1 - can be disregarded.




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� Loosen the 24 bolts on oil pan in diagonal sequence and remove oil pan.

Installing


� Clean all 6 magnets in oil pan recesses. Ensure that magnets make full contact with oil pan.

� Clean sealing surface thoroughly, the previous gasket must be removed completely.

� Tighten oil pan bolts in several stages and in diagonal sequence.

� Install cross member --> 40 - FRONT SUSPENSION .

� Fill up with ATF --> Draining ATF or filling up after performing repairs. � Deactivate jacking mode --> 43 - SELF LEVELING SUSPENSION .

Tightening torques

*Replace bolt.

*Tighten diagonally in stages.

ATF strainer, removing and installing

Removing


� Remove oil pan --> Oil pan, removing and installing.

NOTE:� Observe relevant disposal regulations. � The engine must not be started and vehicle must not be towed without

ATF in transmission.

NOTE:� Replace seals and gaskets. � The drain plug with seal must be replaced.

Component NmDrain plug to oil pan 12 * See noteOil pan to transmission housing 12 * See note

NOTE:� General repair instructions --> General repair instructions . � Read the rules when working on the automatic transmission --> Read the

rules .



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Fig. 171: Identifying Intake Line Of ATF Strainer Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Carefully remove ATF strainer - A - from transmission.

Installing


Fig. 172: Removing/Installing Oil Seal For ATF Strainer From Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC.

Note the following when replacing ATF strainer:

� If installed, carefully remove oil seal for ATF strainer - A - from transmission using a screwdriver or

NOTE:� Replace the ATF strainer if it has been damaged.



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similar.

Fig. 173: Identifying Intake Line Of ATF Strainer Courtesy of VOLKSWAGEN UNITED STATES, INC.

Continue for new and old ATF strainer:

� Press intake line of ATF strainer - A - carefully onto stop into mounting hole in transmission.

� Install oil pan --> Oil pan, removing and installing.


Mechatronics unit , removing and installing

NOTE:� Take care not to damage sealing surface. � For illustration purposes the oil seal is shown with mechatronics unit

removed. � The new ATF strainer is supplied with oil seal installed.

NOTE:� A new ATF strainer is pressed into transmission with oil seal installed.

NOTE:� Always replace mechatronics unit if it is contaminated or faulty. � General repair instructions --> General repair instructions . � Read the rules when working on the automatic transmission --> Read the

rules .



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Removing



Fig. 174: Disconnecting Ground (GND) Strap At Battery Ground (GND) Terminal Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove luggage compartment floor covering.

� Disconnect Ground (GND) wire - arrow - at battery.

� Remove oil pan --> Oil pan, removing and installing. � Remove ATF strainer --> ATF strainer, removing and installing.

CAUTION: Follow steps required when disconnecting battery --> 27 - STARTER, GENERATOR, CRUISE CONTROL .



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Fig. 175: Disconnecting Transmission Control Module (TCM) J217 Electrical Harness Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect electrical connector at transmission by turning fastener cap counter-clockwise - arrow -.

� Touch vehicle ground with your hand (without gloves) to discharge any static electricity.

Fig. 176: Location Of Wiring Harness/Harness Connector Securing Circlip Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Unfasten retaining clip - arrow - for wiring harness connector on outside of transmission housing.


discharge any static electricity by touching vehicle ground or other grounded object with your hand.

� Never touch contacts in 16-pin connector with your hands, as static discharge would damage the control module and mechatronics unit.



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Fig. 177: Removing/Installing Securing Bolts For Mechatronics Unit In Sequence Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove securing bolts for mechatronics unit in sequence - 11... 1 -.

� Remove mechatronics unit together with wiring harness from transmission, at the same time guide out connector for wiring harness.

Fig. 178: Removing/Installing Oil Seal For ATF Strainer From Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing

NOTE:� Only loosen securing bolts marked - 1... 11 -. � If other bolts are loosened, this may affect the operation of the

mechatronics unit or the mechatronics unit could come apart.



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� Make sure that seal - B - is properly inserted and secured.

� Replace O-rings on connector for wiring harness and lightly lubricate with ATF.


� Clip wiring harness - A - onto mechatronics unit - B - by first attaching tab - arrow - on reverse side of wiring harness to mechatronics unit.

� Install wiring harness connector in transmission housing.

� Installation position: flat part of rear shoulder faces downward, the lugs at shoulder are horizontal

NOTE:� If the tab on the reverse side of the wiring harness breaks off, the wiring

harness must be replaced --> Wiring harness in transmission, removing and installing .



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Fig. 180: Inserting Transmission Selector Lever Stud Into Groove On Selector Slide Courtesy of VOLKSWAGEN UNITED STATES, INC.

� While installing mechatronics unit without force, insert transmission selector lever pin - arrow - into groove on selector slide - A - (move selector slide backward and forward if necessary).

Fig. 181: Removing/Installing Securing Bolts For Mechatronics Unit In Sequence Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Tighten securing bolts - 1 - and - 2 - for mechatronics unit to 2 Nm.

� Then tighten securing bolts in specified order - 111 - to 8 Nm.



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Fig. 182: Location Of Wiring Harness/Harness Connector Securing Circlip Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Push retainer clip - arrow - onto wiring harness connector.

� Install ATF strainer --> ATF strainer, removing and installing.

� Install oil pan --> Oil pan, removing and installing.

� Connect battery --> 27 - STARTER, GENERATOR, CRUISE CONTROL .


Wiring harness in transmission, removing and installing

Removing


� Remove mechatronics unit --> Mechatronics unit , removing and installing

� Touch vehicle ground by hand (without gloves) to discharge any static electricity.


discharge any static electricity by touching vehicle ground or other grounded object with your hand.

� Never touch contacts in 16-pin connector with your hands, as static discharge would damage the control module and mechatronics unit.



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� Carefully disconnect wiring harness - A - from mechatronics unit - B -. Make sure to detach tab - arrow - on reverse side of wiring harness from mechatronics unit.

� Carefully disconnect connector - C - from socket - D - of mechatronics unit.

Installing


� Carefully connect connector - C - to socket - D - on mechatronics unit.

� Clip wiring harness - A - onto mechatronics unit - B - by first attaching tab - arrow - on reverse side of wiring harness to mechatronics unit.

� Install mechatronics unit --> Mechatronics unit , removing and installing. � Fill up with ATF --> Draining ATF or filling up after performing repairs.


39 FINAL DRIVE - FRONT DIFFERENTIAL

FRONT FINAL DRIVE GEAR OIL

NOTE:� If the tab - arrow - on the reverse side of the wiring harness breaks off, the

wiring harness must be replaced --> Wiring harness in transmission, removing and installing .



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Front final drive gear oil

Front final drive gear oil level, checking




� Safety goggles

Condition

� Gear oil about 20 ° C (room temperature)

Work sequence

� Drive vehicle onto a four-column hoist or over an inspection pit so that it is absolutely horizontal.



rules .


must first activate the jacking mode --> 43 - SELF LEVELING SUSPENSION




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Fig. 185: Locating Sealing Plug Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove plug - arrow -.

� Oil level must be up to lower edge of filler hole.

� Drain off any excess oil or top off to proper level.

� Tighten new plug to 35 Nm.

Front final drive gear oil, topping off gear oil level after repairs



NOTE:� The screw plug with seal must be replaced.

NOTE:� If the vehicle has been raised on a hoist you must also de-activate the

jacking mode --> 43 - SELF LEVELING SUSPENSION .



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� Safety goggles

Requirements:


Topping off



Fig. 187: Locating Sealing Plug Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove plug - arrow -. � Fill front final drive slowly and evenly over at least 5minutes until gear oil comes out at lower edge of oil

filler hole.



rules .

NOTE:� Before raising the vehicle on a hoist (wheels off the ground) you must first


NOTE:� The top off period of at least 5 minutes is necessary so that the internal oil

level can be balanced out between differential and baffle chamber. � The screw plug with seal must be replaced.



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FRONT FINAL DRIVE, SERVICING

Front final drive, servicing

Front final drive, assembly overview

Fig. 188: Front Final Drive, Assembly Overview

NOTE:� A subsequent level check is not required. � If the vehicle has been raised on a hoist you must also de-activate the



rules .



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1 - Oil seal

� Between final drive and transmission housing

� Replacing --> Final drive/transmission housing oil seal, replacing

2 - Shim

� Behind tapered roller bearing outer race

3 - Outer race for tapered roller bearing

4 - O-ring

� Replace

5 - Screw plug, 35 Nm

� Replace

6 - Flange shaft (right-side)

� Removing and installing --> Flange shaft (right-side), removing and installing

7 - Retaining ring

� Replace

8 - Flange shaft oil seal (right-side)

� Replacing --> Flanged shaft oil seal (right side), replacing

9 - Bolt -23 Nm-

� Follow correct tightening sequence --> Final drive cover O-ring, replacing

10 - Cover for final drive

11 - Shim

� Behind tapered roller bearing outer race

12 - Outer race for tapered roller bearing

13 - O-ring for final drive cover



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� Replacing --> Final drive cover O-ring, replacing

14 - Differential

15 - Spring pin

16 - Selector shaft lever

17 - Oil seal for selector shaft

� Replacing --> Selector shaft oil seal, replacing

18 - Bolt, 23 Nm

19 - Flange shaft (left-side)

� Removing and installing --> Flanged shaft (left side), removing and installing

Flanged shaft (left side), removing and installing






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Fig. 190: Puller T10037 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Puller T10037

Removing

� Transmission is removed


Fig. 191: Removing Bolts On Retaining Bracket For Left-Side Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - arrows - on retaining bracket for left-side flange shaft.



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Fig. 192: Screwing Puller T10037 Onto Differential Cover Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Screw puller T10037 onto differential cover - arrow -.

� Pull out left flange shaft using puller T10037 only until bearing on shaft is removed from transmission housing.

Fig. 193: Removing/Inserting Flange Shaft Into Transmission And Guide Shaft Into Seal On Differential Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Pull left flange shaft - A - out of transmission, making sure that the shaft remains centered in the opening on the differential - arrow -.

NOTE:� If the shaft is not kept centered, the splines of the shaft will fall against the

inner seal between final drive and transmission housing. The seal will be damaged and require replacement --> Final drive/transmission housing oil



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Installing


� Clean flange shaft.

Fig. 194: Removing/Inserting Flange Shaft Into Transmission And Guide Shaft Into Seal On Differential Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Insert flange shaft - A - into transmission and guide shaft into seal on differential - arrow - , keeping it centered.

Tightening torques

Flange shaft (right-side), removing and installing


seal, replacing .

NOTE:� If the shaft is not kept centered, the splines of the shaft will damage the

seal between final drive and transmission housing. The seal will require replacement --> Final drive/transmission housing oil seal, replacing .

Component NmRetaining bracket for left flange shaft to transmission 23



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Removing

� Transmission installed




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� Unbolt axle shaft (right-side) from flange on transmission and tie up.


NOTE:� The right- side axle shaft must be removed on vehicles with a front exhaust

pipe on the right side --> 40 - FRONT SUSPENSION



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Fig. 197: Placing Chisel Or Suitable Spacer Under Flange Shaft And Pulling Flange Shaft Out By Turning Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Place a chisel or distance piece - A - under flange shaft and pull flange shaft out by turning bolt - B -.

Fig. 198: Removing And Installing Securing Ring

NOTE:� If the flange shaft does not come out easily, turn the shaft and insert a bolt

in the opposite hole to assist removal.



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� Replace circlip for flange shaft

� Clamp flange shaft in vise, using jaw protectors. Use new retaining ring - A - to press old retaining ring out of groove in flange shaft.

Installing

Installation is carried out in reverse sequence; note the following:

� Clean flange shaft and seal.

� If seal is damaged, it must be replaced --> Flanged shaft oil seal (right side), replacing.

� Pack space between sealing lip and dust lip half-full with sealing grease G 052 128 A1 .

� Insert flange shaft by hand into splines of differential until splines lock properly into place.

� Press flange shaft in by hand or with mandrel VW295 as far as the stop.

� Bolt right axle shaft to flange shaft --> 40 - FRONT SUSPENSION .

� Check oil level in final drive (front) --> Front final drive gear oil. � Deactivate jacking mode --> 43 - SELF LEVELING SUSPENSION .

Flanged shaft oil seal (right side), replacing

NOTE:� The circlip on the flange shaft should click into place.



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Fig. 199: Identifying Special Tools - Flanged Shaft Oil Seal (Right Side), Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC.



� Extractor lever VW681


Procedure





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� Remove flange shaft (right-side) --> Flange shaft (right-side), removing and installing.

Fig. 200: Removing Flange Shaft Oil Seal Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Pull out flange shaft oil seal.

� Lubricate outer circumference of seal with gear oil

Fig. 201: Driving New Seal In Onto Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Drive new seal in onto stop (take care to keep seal straight).

� Installation position: the open side of the seal should face the transmission.


� Install flange shaft (right-side) --> Flange shaft (right-side), removing and installing.

� Check oil level in final drive (front) --> Front final drive gear oil.

rules .



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Final drive cover O-ring, replacing




Procedure





Fig. 203: Removing/Installing Bolts On Final Drive Cover In Sequence Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts on final drive cover in sequence - 11... 1 - and remove cover together with outer race for



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tapered roller bearing and shim.

Fig. 204: Identifying Cover For Front Final Drive And O-Ring Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Replace O-ring - arrow -.

Note the following if the outer race for tapered roller bearing and the shim have dropped out of the final drive cover:

� Lubricate shim and outer race for tapered roller bearing with gear oil and insert in final drive cover as far as stop.


NOTE:� Thickness of shim has been measured to fit; the shim must not be

replaced with another shim of different thickness.



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� Tighten bolts of final drive cover as follows.


� Check oil level in final drive (front) --> Front final drive gear oil. � Deactivate jacking mode --> 43 - SELF LEVELING SUSPENSION .

Final drive/transmission housing oil seal, replacing

Fig. 206: Identifying Special Tools - Final Drive/Transmission Housing Oil Seal, Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC.

Step Tightening sequence

I � Tighten bolts - 1 - and - 2 - to 3 Nm.

II � Tighten bolts - 1... 11 - to 23 Nm in the sequence indicated.



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� Extractor lever VW681


Requirements

� Transmission is removed

� Transmission mounted on assembly stand --> Securing transmission to assembly stand.

Procedure




� Remove bolts on final drive cover in sequence - 11... 1 - and remove cover together with outer race for tapered roller bearing and shim.

CAUTION: Do not place transmission down on ATF cooler or oil pan.

NOTE:� A faulty seal allows gear oil to enter the torque converter bellhousing. � General repair instructions --> General repair instructions . � Read the rules when working on the automatic transmission --> Read the

rules .

NOTE:� The thickness of shim has been measured to fit; the shim must not be




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� Remove differential.

Fig. 208: Identifying Tapered Roller Bearing Outer Race For Differential And Shim Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove tapered roller bearing outer race - 1 - for differential and shim - 2 - (behind outer race) from transmission housing by hand.

� Remove flange shaft (left-side) --> Flanged shaft (left side), removing and installing.

Fig. 209: Pulling Out Oil Seal Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove seal.

NOTE:� The thickness of shim has been measured to fit; the shim must not be


NOTE:� The oil seal extractor lever VW681 must be applied behind the two sealing

lips of the oil seal. Do not apply the lever to the outer circumference of the seal, as this would damage the sealing surface in the transmission. Guide the lever carefully when removing the seal.



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� Examine oil seal seat in transmission housing for damage; reface surface if necessary.

� Lightly lubricate outer circumference and sealing lip of oil seal with gear oil.

Fig. 210: Driving In New Oil Seal As Far As Stop Using Thrust Piece T10139 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Drive new oil seal as far as stop using thrust piece T10139.

Fig. 211: Identifying Tapered Roller Bearing Outer Race For Differential And Shim Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Insert shim - 2 - and tapered roller bearing outer race - 1 - for differential onto stop in transmission housing by hand.

NOTE:� Push seal onto thrust piece with the protruding sealing lip on the seal

facing toward the tool.

NOTE:� Make sure that shim and outer race are kept straight when inserting.



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Fig. 212: Identifying Cover For Front Final Drive And O-Ring Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Renew O-ring - arrow -. � Install differential in transmission housing.

Note the following if the outer race for tapered roller bearing and the shim have dropped out of final drive cover:

� Lubricate shim and outer race for tapered roller bearing with gear oil and insert in final drive cover as far as stop.


� Tighten bolts of cover for final drive as follows.




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� Install flange shaft (left-side) --> Flanged shaft (left side), removing and installing.


� Check oil level in final drive (front) --> Front final drive gear oil.

Selector shaft oil seal, replacing


Fig. 214: Thrust Piece T10135 Courtesy of VOLKSWAGEN UNITED STATES, INC.


Procedure




� Remove transmission support (left-side).

All models:


II � Tighten bolts - 1...11 - to 23 Nm in the sequence indicated.


rules .



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2:34:19 AM



Fig. 216: Driving Out Spring Dowel Sleeve At Lever/Shift Rod Of Travel Toward Front Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Drive out roll pin - 1 - at selector shaft lever - 2 - - arrow - until it is possible to detach selector shaft lever from selector shaft.




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Fig. 217: Prying Seal Out With A Screwdriver Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Push a small screwdriver through seal and pull it out.

� Lubricate outer circumference and space between sealing lips of seal with ATF.

� Install new seal onto selector shaft.

� Installation position: the open side of the seal should face transmission.

Fig. 218: Pressing On New Oil Seal Using Thrust Piece T10135 And Assembly Lever As Far As Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Press on new oil seal using thrust piece T10135 and assembly lever - A - as far as stop; make sure that oil seal remains straight.

� Before installing, drive roll pin in selector shaft lever back through lever in opposite direction.

� Push selector shaft lever onto selector shaft and drive in roll pin.

NOTE:� To prevent slippage when pressing in oil seal, place something as a base

(e.g. piece of rubber) between assembly lever and subframe - arrow -.



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� Press on ball socket - 1 - of selector lever cable onto selector shaft lever.


TRANSFER GEAR OIL LEVEL

Transfer gear oil level

Transfer gear oil level, checking


NOTE:� Do not bend the selector shaft lever when pressing on the ball socket, as

otherwise it will no longer be possible to precisely adjust the gear selector mechanism


rules .



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� Safety goggles

Condition


Work sequence








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Fig. 221: Transfer Gear Oil Plug Courtesy of VOLKSWAGEN UNITED STATES, INC.


� Oil level must be up to lower edge of filler hole.

� Drain off any excess oil or top off to proper level; specification --> Transfer gear.


Transfer gear oil, topping off after repairs




� Safety goggles

Test conditions


� Cover was removed from Transfer gear and all gear oil was thereby drained.

Work sequence

NOTE:� The plug with seal must be replaced.





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Fig. 223: Transfer Gear Oil Plug Courtesy of VOLKSWAGEN UNITED STATES, INC.


� Fill transfer gear slowly and evenly over at least 5minutes with gear oil (specification --> Transfer gear ).





NOTE:� The engine must not be started and vehicle must not be towed without

gear oil in transmission.

NOTE:� The top off period of at least 5 minutes is necessary so that the internal oil

level can be balanced out between Torsen differential and baffle chamber. � The plug with seal must be replaced.

NOTE:� A subsequent level check is not required. � If the vehicle has been raised on a hoist you must also de-activate the




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TRANSFER GEAR, SERVICING

Transfer gear, servicing

Torsen differential cover, removing and installing




� Safety goggles

Removing



CAUTION: Do not run the engine or tow the vehicle if the Torsen differential is removed or if the gear oil has been drained from the transmission.

CAUTION: Do not run the engine or tow the vehicle if the Torsen differential is removed or if the gear oil has been drained from the transmission.


rules .



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Fig. 226: Loosening Clamping Sleeve Courtesy of VOLKSWAGEN UNITED STATES, INC.



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� Disconnect exhaust system at clamp - arrow -.

Fig. 227: Locating Bolts At Center Bracket For Front Exhaust Pipe Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - arrows - at center bracket for front exhaust pipe.

� Tie up front exhaust pipe to side or support from below.

Fig. 228: Tunnel Cross Member And Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - arrows - at tunnel cross member.

� Remove tunnel cross member with center bracket for front exhaust pipe.

On vehicles with 8-cyl. engine:

NOTE:� The flexible pipe connection (de-coupling element) on the front exhaust

pipe must not be bent by more than 10 ° - otherwise it can be damaged.



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� Remove tunnel cross member - 1 -.

All models:

Fig. 230: Removing/Installing Heat Shield For Driveshaft Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove heat shield - A - for drive axle - arrows -. � Remove bolts at transmission/drive shaft flange.

� Slide drive shaft together toward rear final drive. The constant velocity joints can be moved axially.

� Tie up drive shaft to side.



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Fig. 231: Loosening/Tightening Securing Bolts For Cover For Torsen Differential In Sequence Courtesy of VOLKSWAGEN UNITED STATES, INC.


� Loosen securing bolts for cover for Torsen differential in sequence - 6 to 1 - and remove; allow gear oil to drain out.


NOTE:� The cover is not equipped with a drain plug; drain the gear oil by removing

the cover.

CAUTION: Pull the Torsen differential cover backward from the transmission housing slowly and carefully. The Torsen differential may otherwise fall out of the transmission.



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Fig. 232: Securing Torsen Differential And Baffle Plate To Prevent Them From Dropping Out Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Secure Torsen differential - B - and baffle plate - A - to prevent them dropping out, or pull them off the output shaft toward rear.

Fig. 233: Identifying If Torsen Differential And Baffle Plate Have Been Removed Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing


Note the following if the Torsen differential - B - and baffle plate - A - have been removed:

NOTE:� Replace O- ring on Transfer gear cover.



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� Clean baffle plate, lubricate with gear oil and insert in transmission.

� Installation position: tongue - A - on baffle plate should be positioned on transmission so that the side lugs are located above opening - B -.

Fig. 234: Securing Torsen Differential And Baffle Plate To Prevent Them From Dropping Out Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Install Torsen differential - B - onto output shaft splines (turn slightly at same time).

� Check whether attached Torsen differential can be turned manually.

� Check whether tongue - arrow - on baffle plate is still located properly.

� Place cover for Torsen differential with shaft installed onto Torsen differential, turn slightly if necessary.

NOTE:� Check installation position of tongue on baffle plate - arrow - again.



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Fig. 235: Loosening/Tightening Securing Bolts For Cover For Torsen Differential In Sequence Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Tighten cover bolts for Torsen differential as follows.

� Install drive shaft --> 39 FINAL DRIVE, REAR DIFFERENTIAL . � Install exhaust system -->





.

� Top off Transfer gear oil --> Transfer gear oil, topping off after repairs

Tightening torques



II � Tighten bolts - 1 to 6 - to 23 Nm in the sequence indicated.

Component Nm



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Flanged shaft oil seal (rear), replacing

Fig. 236: Identifying Special Tools -- Flanged Shaft Oil Seal (Rear), Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC.


� Thrust plate VW401

� Thrust plate VW402

� Thrust pad VW447 i

� Punch VW409

Cross member to body 23Heat shield for drive shaft to transmission 23



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� Pressure application device T10136

Procedure

� Remove Torsen differential cover --> Torsen differential cover, removing and installing.

Fig. 237: Removing/Installing Circlip On Inner Side Of Cover Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove circlip - arrow - on inner side of cover.

Fig. 238: Using Punch VW 409 To Press Flange Shaft Out Of Torsen Differential Cover By Placing Cover On Thrust Plate VW 401 And Thrust Plate VW 402 Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:� The circlip locates the flange shaft on the bearing in the cover.



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� Using press tool VW409 , press flanged shaft out of Torsen differential cover by placing cover on thrust plate thrust plate VW401 and thrust plate VW402.

Fig. 239: Prying Out Oil Seal Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Pry out oil seal.

Fig. 240: Placing Torsen Differential Cover On Pressure Application Device T10136 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Place cover - A - for Torsen differential on pressure application device T10136.

� Lubricate outer circumference of seal with gear oil

NOTE:� Hold flange shaft - A - with one hand to prevent if from falling.

NOTE:� To prevent damage to the housing, place something underneath (e.g.

metal bar - A - ).

NOTE:� The peg in the middle of the tool is centered and faces upward in the

cover. It serves as a guide and stop for press tool T10136/1.



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� Push new seal onto press tool T10136/1.

� Installation position: open side of seal should face cover.

Fig. 241: Inserting Pressure Application Device T10136/1 With Seal Into Cover From Above Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Insert press tool T10136/1 with seal into cover from above.

� Drive new seal in onto stop (take care to keep seal straight).


NOTE:� The peg of the pressure application device T10136 serves as a guide from

below and also as a stop for press tool T10136/1.



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Fig. 242: Pressing Flange Shaft Using Punch VW 409 And Thrust Pad VW 447 I Into Torsen Differential Cover By Placing Cover On Thrust Plate VW 401 And Thrust Plate VW 402 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Press flange shaft with press tool VW409 and thrust pad VW447 i into cover for Torsen differential. To do so, place cover on thrust plate VW401 and thrust plate VW402.

Fig. 243: Removing/Installing Circlip On Inner Side Of Cover Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Install circlip - arrow - in groove of flange shaft on inner side of cover.

� Install cover for Torsen differential --> Torsen differential cover, removing and installing.

� Top off oil in Transfer gear --> Transfer gear oil, topping off after repairs

NOTE:� Only insert flange shaft as far as necessary to install circlip.



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00 technical data - planet

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