How to replace Transaxle on Audi A4 & VW passat models?

The Transaxle Replacing procedure is similar for both Audi and passat car models.


Transaxle Removal & Installation details are as follows:---

1. Note the radio security code.
2. Disconnect the negative battery cable.
3. Remove the engine trim covers.
4. On 1.8L engines, attach engine support Tool Nos. 10-222A/3, 10-222A and 10-222A/1 between the engine and the inner fenders and support the engine.
5. On 2.8L V6 engines, attach engine support Tool Nos. 2024A, 10-222A and 10-222A/1 between the engine and the inner fenders and support the engine.
6. Loosen the outer axle mounting bolts and front wheel lug bolts, BEFORE lifting and supporting the vehicle.
7. Raise and safely support the vehicle.
8. Remove the front wheels.
9. Remove the lower engine shield.
10. Remove the axle noise insulation brackets and trays and the right axle protective plate.
11. Remove the halfshafts.
12. Disconnect the electrical connectors for the multi-function switch, transmission wiring, and the speedometer speed sensor.

NOTE

Turn the lock-ring counterclockwise to disconnect the transmission wire connector.

1. Matchmark the gear selector cable bracket where it attaches the transmission housing and remove the bracket.
2. Remove the front half of the exhaust system making sure to disconnect any electrical connectors as necessary.
3. On 2.8L V6 engines, remove the alternator cooling duct, then disconnect the starter and alternator wires from the guide bracket and remove the alternator.
4. Place a suitable drain pan under the transmission and remove the ATF cooling lines from the transmission and seal the lines and the transmission.
5. Remove the gear selector cable from the selector shaft.
6. Remove the starter motor allowing access to the torque converter mounting bolts.
7. Remove the torque converter mounting bolts rotating the engine as necessary to access the bolts through the starter drive gear opening.
8. Remove the lower engine-to-transmission mounting bolts.
9. Support the transmission with a suitable transmission jack.
10. Remove the left and right support mounts and support plates.
11. Remove the multi-function switch and cover its installation hole.
12. Matchmark the subframe to the under body and remove all the subframe-to-body mounting bolts EXCEPT the front two bolts just in front of and to the outside the sway bar mounts. Loosen those two bolts three revolutions each allowing the rear of the subframe to drop about 5 ⁷ / ₈ inches (150mm).
13. Lower the transmission jack slightly to gain access to the top transmission-to-engine mounting bolts and remove the bolts.
14. Press the transmission from the engine while pressing the torque converter from the drive plate. Press the torque converter against the transmission pump and secure the torque converter to prevent it from coming out.
15. Pivot the rear of the transmission downward between the subframe and the underbody, then lower the transmission from the engine.

Fig. The engine must be supported during transmission removal using a suitable tool

Fig. An exploded view of the left and right brackets and mounts, which are removed during transmission removal

Fig. The transmission-to-engine mounting bolts vary in length. The lengths vary by transmission type as well

Fig. The transmission-to-engine mounting bolt location, length and torque specification for the 01V transmission

Fig. The engine must be supported using a suitable support tool and sling

Fig. The bolt location and torque for the A4 V6

Fig. The bolt location and torque for the Passat V6

To install:

1. Guide the transmission between the subframe and the vehicle aligning the transmission with the engine.
2. Install the upper transmission-to-engine mounting bolts and torque to 48 ft. lbs. (65 Nm).
3. Raise the transmission and engine and install the subframe making sure to align the matchmarks made during disassembly.
4. Torque the subframe as follows:

Subframe-to-body:

M8 bolt (replace): 17ft. lbs. (23 Nm)

M10 bolt (replace): 44ft. lbs. (60 Nm)

M12 bolt (replace): Step 1: 81ft. lbs. (110 Nm) Step 2: 90° ( ¹ / ₄ turn)

1. Install the left, then the right transmission supports and mounts.
2. Install the lower transmission-to-engine bolts and torque as follows:

Transmission-to-engine bolts:

M10: 33 ft. lbs. (45 Nm)

M12: 48 ft. lbs. (65 Nm)

1. Tighten the torque converter bolts, rotating the crankshaft as necessary to access the threaded holes.
Torque converter to drive plate: 63 ft. lbs. (85 Nm)
2. Install the halfshafts. DO NOT tighten the outer mounting bolt until the vehicle is resting on the ground.
3. The balance of assembly is in reverse order of removal noting the following component torque.
ATF line-to-transmission: 15ft. lbs. (20 Nm)
Bracket for ATF line: 84 inch lbs. (10 Nm)
Halfshaft-to-transmission: 59 ft. lbs. (80 Nm)
Wheel bolts to wheel hub: 89ft. lbs. (120 Nm)
4. Upon assembly, check the final drive oil level and the transmission fluid level and top off as necessary.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Upper engine-to-transaxle bolts
3. Using an engine support tool, secure it to the engine and the vehicle.
4. Remove or disconnect the following:
   
   
   Both top bolts at the front of the engine

   Starter

   Torque converter-to-driveplate bolts through the starter opening

   Torque converter cover plate

   Coolant hoses at the transmission cooler by clamping them off
5. Support the halfshafts
6. Remove or disconnect the following:
   
   
   Inner halfshaft-to-transaxle bolts

   Remove the ball joint and the support

   Oil filler tube from the oil pan and drain the fluid

   Exhaust pipe-to-transaxle bracket

   Selector cable bracket from the transaxle

   Selector cable circlip and the cable at the transaxle shift lever

   Accelerator cable bracket and the cable from the operating lever

   Center bolt, from the transaxle mount.
7. Using the engine support tool, lift the engine slightly.
8. Remove the throttle cable bracket bolts and the bracket.
9. Support the transaxle and lift it slightly.
10. Remove or disconnect the following:
    
    NOTE

    Be sure to secure the torque converter.
    
    
    
    
    Lower transaxle-to-engine bolts

    Transaxle from the engine

To install:

1. Installation is the reverse of the removal procedure, while using the following torque values:
   
   
   Transaxle flange bolts: 41 ft. lbs. (56 Nm)

   Subframe bolts: 52 ft. lbs. (71 Nm)

   Transaxle mount center bolt: 30 ft. lbs. (40 Nm)

   Torque converter bolts: 63 ft. lbs. (85 Nm)

   Halfshaft bolts: 33 ft. lbs. (45 Nm)

   Ball joint bolts: 48 ft. lbs. (65 Nm)

1. Disconnect the negative battery cable.
2. Remove the upper engine-to-transaxle bolts. Raise and support the vehicle safely.
3. Using a suitable engine support tool, secure it to the engine and the vehicle.
4. At the front of the engine, remove both top bolts. Remove the starter.
5. Through the starter opening, remove the torque converter to drive plate bolts and remove torque converter cover plate.
6. Clamp off the coolant hoses at the transmission cooler and remove the hoses from the cooler.
7. Remove the inner halfshaft-to-transaxle bolts. Using a wire, tie up the halfshafts.
8. At the left control arm, mark the position of the ball joint and remove the ball joint and the support.
9. Place an oil catch pan under the transaxle, remove the oil filler tube from the oil pan and drain the fluid.
10. Remove the exhaust pipe-to-transaxle bracket.
11. Remove the selector cable bracket from the transaxle. At the transaxle shift lever, remove the selector cable circlip and the cable.
12. At the transaxle, remove the accelerator cable bracket and the cable from the operating lever.
13. Remove the center bolt, from the transaxle mount. Using the engine support tool, lift the engine slightly.
14. Remove the throttle cable bracket bolts and the bracket.
15. Support the transaxle and lift it slightly. Remove the lower transaxle-to-engine bolts.
16. Separate the engine from the transaxle and lower it from the vehicle. Be sure to secure the torque converter.

To install:

1. When installing the transaxle, should the torque converter slip off the 1-way clutch support, the oil pump shaft could be pulled from the oil pump. This may cause severe damage when bolting the transaxle to the engine. Be sure the torque converter is properly positioned before installing the bolts.
2. Tighten the engine-to-transaxle bolts to 41 ft. lbs. (56 Nm), the subframe bolts to 52 ft. lbs. (71 Nm) and the transaxle mount center bolt to 30 ft. lbs. (40 Nm).
3. Install the torque converter-to-driveplate bolts and tighten to 63 ft. lbs. (85 Nm). Install the cover plate.
4. Install the halfshaft-to-transaxle bolts and tighten to 33 ft. lbs. (45 Nm).
5. Connect the ball joint to the control arm and tighten the bolts to 48 ft. lbs. (65 Nm).
6. Install the exhaust system. When installing the exhaust, tighten the clamps after making sure everything is properly positioned to minimize vibration.
7. Connect the hoses to the oil cooler. Install the oil filler tube and refill the transaxle.
8. Connect and adjust the selector cable as required.
9. Connect and adjust the accelerator linkage and align the engine-to-transaxle mounts, if necessary.
10. Check all fluid levels and top off as necessary.
11. Reconnect the negative battery cable.
12. Enter the radio security code.

1. Before servicing the vehicle, refer to the precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Engine cover

   Air cleaner duct

   Air cleaner assembly

   Upper engine-to-transaxle bolts
3. Using an engine support tool, secure it to the engine and the vehicle.
4. Remove or disconnect the following:
   
   
   Front wheels

   Transmission range switch, connector and bracket

   Heat shields for drive shafts

   Drive shaft from transmission flanges

   Speed sensor connectors (mark for reinstallation)

   Both oxygen sensors (mark left and right for reinstallation)

   Both top bolts at the front of the engine

   Starter

   Torque converter-to-driveplate bolts through the starter opening

   Torque converter cover plate

   Coolant hoses at the transmission cooler by clamping them off
5. Support the halfshafts
6. Remove or disconnect the following:
   
   
   Inner halfshaft-to-transaxle bolts

   Remove the ball joint and the support

   Oil filler tube from the oil pan and drain the fluid

   Exhaust pipe-to-transaxle bracket

   Selector cable bracket from the transaxle

   Selector cable circlip and the cable at the transaxle shift lever

   Accelerator cable bracket and the cable from the operating lever

   Center bolt, from the transaxle mount.
7. Using the engine support tool, lift the engine slightly.
8. Remove the throttle cable bracket bolts and the bracket.
9. Support the transaxle and lift it slightly.
10. Remove or disconnect the following:
    
    NOTE

    Be sure to secure the torque converter.
    
    
    
    
    Lower transaxle-to-engine bolts

    Transaxle from the engine

To install:

1. Installation is the reverse of the removal procedure, while using the following torque values:
   
   
   Transaxle flange bolts: 41 ft. lbs. (56 Nm)

   Subframe bolts: 52 ft. lbs. (71 Nm)

   Transaxle mount center bolt: 30 ft. lbs. (40 Nm)

   Torque converter bolts: 63 ft. lbs. (85 Nm)

   Halfshaft bolts: 33 ft. lbs. (45 Nm)

   Ball joint bolts: 48 ft. lbs. (65 Nm)

   Starter motor bolts: 48 ft. lbs. (65 Nm)

1. Before servicing the vehicle, refer to the precautions section.
2. Place gearshift in neutral.
3. Before servicing the vehicle, refer to the precautions section.
4. Place transaxle in neutral.
5. Remove or disconnect the following:
   
   
   Negative battery cable

   Engine covers

   Engine top cover over cylinder head

   Hoses and connectors from air filter housing

   Air filter housing

   Battery and battery carrier

   Selector lever off selector lever shaft

   Selector lever cable

   Multi-function switch connector

   Cables and connectors from starter

   Starter

   ATF cooler hoses after clamping off
6. Install Engine Support bracket 10-222A and supports 10-222A1.
7. Install Retainer 3180 to right engine lifting eye and attach it to support bracket 10-222A.
8. Lift engine slightly with spindle of support bracket 1022A.
9. Remove or disconnect the following:
   
   
   Ground cable at transaxle

   Engine to transaxle mounting bolts accessible from above

   Engine undercover

   Front wheels

   Left drive shaft

   Left side sound insulator

   Power steering line at transmission

   Front tubular cross member (if equipped)

   Cross brace at subframe

   Sway brace
10. Press out the right ball joint.
11. Remove right drive shaft heat shield.
12. Disconnect right drive shaft from transaxle, but not from wheel hub
13. Tie the right drive shaft up out of the way.
14. Remove six torque converter nuts, turning crankshaft 60° each time to access nuts.
15. Remove exhaust pipe clamps and suspend exhaust pipe under vehicle.
16. Remove electrical connectors from transaxle.
17. Remove transaxle console support bracket.
18. Lower engine and transaxle assembly approximately 2 inches (50 mm).
19. Position transaxle jack so it can support full weight of transaxle.
20. Remove the engine to transaxle mounting bolts.
21. With the aid of an assistant slide transaxle back slightly until torque converter can be secured in place, then lower transaxle and move away from vehicle.

To install:

1. Installation is the reverse of the removal procedure, while using the following torque values:
   
   
   Transaxle to engine M12 bolts: 59 ft. lbs. (80 Nm)

   Transaxle to engine M10 bolts: 33 ft. lbs. (45 Nm)

   Starter bolts: 59 ft. lbs. (80 Nm)

   Subframe bolts: 74 ft. lbs. (100 Nm) plus90°

   Sway brace side bolts: 15 ft. lbs. (20 Nm) plus 90°

   Sway brace bottom bolts: 30 ft. lbs. (40 Nm) plus 90°

These details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html