Transmission, Removing, 4.2L FSI Engine

Special tools and workshop equipment required

Engine and Gearbox Jack:VAS6931
Engine Bung Set:VAS6122
Crankshaft Socket:T40058
Gearbox Support:T40173

Preparing the Gearbox Support:T40173 :

Fig 1: Bracket Attached To -1- Must Be Removed

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-- The bracket attached to -1- must be removed.

-- The bracket -2- must be turned so that the longer side faces up as illustrated.

Removing

Fig 2: Disconnecting Battery

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-- Position the front wheels so they are straight.

CAUTION:

Risk of damaging electronic components when disconnecting the battery.

Complete the steps for disconnecting the battery.

-- Disconnect the battery. Refer to Battery, Disconnecting and Connecting .

-- Remove the engine cover. Refer to the appropriate Service Information .

Fig 3: Identifying Engine Cover

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-- Remove the noise insulation -1 and 2-. Refer to Noise Insulation, Removing and Installing .

Fig 4: Identifying Front Noise Insulation

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-- Remove the right coolant pipe on the transmission. Refer to the appropriate Service Information .

Fig 5: Identifying Coolant Pipe

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-- Remove the driveshaft. Refer to DRIVESHAFT, REMOVING FROM REAR FINAL DRIVE AND INSTALLING [0BC, 0BD, 0BE, 0BF] or DRIVESHAFT, REMOVING FROM REAR FINAL DRIVE AND INSTALLING [0BF & 0BE] .

Fig 6: Counter Hold Rear Driveshaft Using Counterhold Tool T10172 And Adapters T10172/5

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-- Remove the left and right front muffler. Refer to the appropriate Service Information .

Fig 7: Identifying Left Front Muffler Nuts And Bolts

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-- Remove the ATF cooler. Refer to ATF COOLER, REMOVING AND INSTALLING .

-- Remove the transmission mount. Refer to TRANSMISSION MOUNT, REMOVING AND INSTALLING .

-- Remove the connectors -3 and 4- for the heated oxygen sensors from the bracket.

Fig 8: Identifying Oxygen Sensors Location, Cylinder Bank 2 (left)

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NOTE:

Ignore items -1 and 2-.

-- Remove the connectors -1 and 2- for the heated oxygen sensors from the bracket.

Fig 9: Identifying Oxygen Sensors Location, Cylinder Bank 1 (right)

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NOTE:

Ignore items -3 and 4-.

-- Disconnect the connector -1-.

Fig 10: Identifying Transmission Coolant Valve -N488- -

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-- Loosen the clamp -3- and remove the coolant hose.

NOTE:

Ignore -2 and arrows-.

-- Remove the bolts -2 through 5- connecting the engine to transmission. They are accessible from above.

Fig 11: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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NOTE:

Catch any leaking ATF with a cloth.

-- Remove the bolts -arrows- and remove the ATF pipe -1- from the transmission.

Fig 12: Identifying ATF Pipe And Bolts

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-- Seal the open lines and connections with clean plugs from the Engine Bung Set:VAS6122 .

CAUTION:

There is a risk of destroying the transmission control module (Mechatronic) with static discharge.

Do not touch contacts in transmission connector with hands.

-- To discharge static electricity, touch the transmission housing (without wearing gloves).

-- Disconnect the connector on transmission by rotating screw connections counter-clockwise in the direction of -arrow-.

Fig 13: Disconnecting Connector From Transmission

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-- Free up the electrical wiring harness on the transmission.

-- Remove the bolts -arrows- and then remove the heat shield from the right drive axle.

Fig 14: Drive Axle Heat Shield

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-- Remove the bolts -arrows- and the left drive axle heat shield.

Fig 15: Identifying Bolts & Left Drive Axle Heat Shield

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-- Remove the left and right drives axles from the transmission flange shafts. Refer to DRIVESHAFT, REMOVING FROM REAR FINAL DRIVE AND INSTALLING [0BC, 0BD, 0BE, 0BF] or DRIVESHAFT, REMOVING FROM REAR FINAL DRIVE AND INSTALLING [0BF & 0BE] .

Fig 16: Drive Axle Bolts

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-- Remove the steering intermediate shaft from the steering gear and push them both upward. Refer to Steering Intermediate Shaft, Removing and Installing .

Fig 17: Locating Steering Column Universal Joint Bolt

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-- Disconnect the connectors -2- from the Engine Speed Sensor -G28- and free up the wire.

Fig 18: Engine Speed Sensor -G28-

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NOTE:

Ignore item -1-.

-- Release the retainers in the direction of -arrows A- and slide the sleeve -1- in direction of -arrow B-.

Fig 19: Identifying Emergency Release Cable

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-- Disconnect the rear emergency release cable from the front emergency release cable in the direction of -arrow C-.

-- Remove the lower cover -1- from the transmission in the direction of -arrow-.

Fig 20: Identifying Transmission Lower Cover

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-- Insert the Crankshaft Socket:T40058 guide pins as follows:

Fig 21: Guide Pin & Adapter T40058

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The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

-- Counterhold the torque converter by the crankshaft drive plate using the Crankshaft Socket:T40058 when loosening the bolt.

Fig 22: Locating Torque Converter Bolts

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NOTE:

When mounting, turn the crankshaft only in the direction of engine rotation in the direction of -arrow-.

-- Remove the six torque converter bolts -arrow- while turning the crankshaft 60° further in the direction of engine rotation.

Fig 23: Identifying Clutch Module First Bolt Installation Location

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-- Remove the bolt -1- from the starter.

Fig 24: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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-- Remove the starter from the transmission and leave it in the installation position.

-- Remove the remaining engine/transmission bolts -6 through 11- but leave one bolt -7- installed hand-tight.

Fig 25: Do Not Set T40173 On ATF Pan

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CAUTION:

Danger of leaks in the ATF pan.

The Gearbox Support:T40173 must not be set on the ATF pan.

-- Place the Engine and Gearbox Jack:VAS6931 with the prepared Gearbox Support:T40173 under the transmission.

-- The transmission support must be placed at the front as follows:

The bracket -2- fits into the dual-mass flywheel on the transmission housing on the left side of the transmission.
The transmission mount is positioned on the differential housing on the right side of the transmission. Insert a flat piece of rubber -1- in between to protect the housing.

-- Secure the transmission with a tensioning strap -1-.

Fig 26: Securing Transmission With A Tensioning Strap

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NOTE:

The Gearbox Support:T40173 is not illustrated.

-- Remove the bolts from the tunnel crossmember -arrows-.

Fig 27: Identifying Crossmember & Bolts

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-- Remove the last bolt from the transmission to engine connection.

Fig 28: Securing Transmission With A Tensioning Strap

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-- Press the transmission off the engine and lower it carefully using the Engine and Gearbox Jack:VAS6931 .