Volkswagen Workshop Service and Repair Manuals

Removing gearbox, Passat 2011 ► with 3.6 l V6 engine (all-wheel drive) Brief description The gearbox is removed downwards together with the bevel box. »From above« Remove battery, air filter and starter. The coolant hoses must be clamped off. Left subframe mounting is removed and engine and gearbox supported. »From below«:

Remove -subframe- together with -pendulum support-, -steering box- and -both suspension links-.

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Adjustment plate -3282/42 A-

t	Socket -T10061-

t	Hose clamps up to 40 mm -3093-, if available, otherwise hose clamps up to 25 mm -3094-

t	Gearbox support -3282-

t	Insert tool, 18 mm -T10179-

Special tools and workshop equipment required t  Bracket -T10013- t  Adapter -10 - 222 A /18- t  2 tensioning belts -T10038- t  Engine and gearbox jack -V.A.G 1383 A- Removing: –  Raise vehicle. All 4 supports of lifting platform must be at same height. –  Move selector lever to position »P« position. –  Disconnect battery → Rep. gr.27.

–  Remove complete air filter housing → Rep. gr.24, and remove bracket beneath that. –  Unbolt earth strap from bracket.

–  Release mechatronic unit connector -1- by turning and pull off connector. –  Remove starter -A- → Electrical system; Rep. gr.27. It is advisable to remove the »lower« bolt first.

–  Remove selector lever cable from gearbox. Use pliers to remove the securing clip on the cable support bracket. Do not use a sharp-edged lever, as the rubber grommet on the cable could be damaged.

Both securing clips must be later renewed when cable is adjusted. –  Remove cable with great care from cable support bracket on gearbox. Do not bend cable. Cable can also be removed later on when gearbox is being lowered. Then observe cable whilst lowering gearbox. During later installation, do not clip »small« securing clips on until cable has been checked and adjusted.

–  Clamp off coolant hoses using hose clamps to 40 mm -3093- or hose clamps to 25 mm -3094- and remove.

–  Unbolt coolant line from engine -1- and -2-.

–  Insert bracket -T10013- in eye of crankcase.

–  Remove all upper engine/gearbox connecting bolts.

The following tools are appropriate for this: –  Remove noise insulation and lower part of front left wheel housing liner → General body repairs, exterior; Rep. gr.66.

–  Unbolt wiring retainer from front of »black« gearbox cover -arrows- (2 nuts M6). Specified torque: 10 Nm –  Unbolt left and right drive shaft from gearbox → Rep. gr.40.

–  Secure both drive shafts on suspension strut with tensioning belts -T10038-. The surface protection of the shafts must not be damaged.

Next remove -subframe- together with -pendulum support- and -both suspension links- and -steering-. → Running gear, axles, steering; Rep. gr.40

–  Mark position of propshaft with flexible coupling relative to bevel box flange with paint. –  Unbolt propshaft from bevel box -arrows- → Rep. gr.39. –  Push front propshaft tube to stop.

The -seal- in the propshaft must not be damaged. If seal is damaged, propshaft must be renewed.

–  Remove heat shield above right drive shaft -1- → Rep. gr.40.

–  Remove bolts -1- for gearbox carrier to bevel box. –  Loosen bolts -2-. Torque setting 40 Nm –  Remove filler pieces from upper edges of both wings.

–	Place support bracket -10 - 222 A- onto upper longitudinal member.

Caution The support bracket must not be placed on the wings. Otherwise, these can be damaged. –  Support engine and gearbox with support bracket -10 - 222 A- and hooks -10 - 222 A /10-. Do not raise.

–  Remove all bolts -1- and -2- for bracket -A-.

–  Then lower engine/gearbox assembly to dimension -a- using spindle of support bracket -10 - 222 A-. Dimension -a- = about 20mm

Remove bracket -arrow-. –  Remove all connecting bolts except one which is in an easily accessible place between engine and gearbox. –  Set up gearbox support -3282- with adjustment plate -3282/42 A-. –  Move engine and gearbox jack -V.A.G 1383 A- under gearbox and support gearbox. Do not raise. The gearbox is separated from the engine in this position. –  Remove last engine/gearbox connecting bolt. –  Press gearbox off engine, »observing selector lever cable« and lower gearbox. Transporting gearbox and securing to assembly stand → Chapter. Install gearbox.