2001-2003 Transmission Removal and Installation Manual

2001-2003 Transmission Removal and Installation Manual
2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
2001-03 AUTOMATIC TRANSMISSIONS
Removal & Installation - 01P
APPLICATION
TRANSAXLE APPLICATION
Application
Eurovan
Transaxle Model
01P
REMOVAL & INSTALLATION
VEHICLES WITH SHORT FRONT END
NOTE:
On Eurovans from January 1996, the front end and assembly mounts have
been modified. The front end can be either a long or short front end version.
Long front end vehicle (distance "a") is 3.54" (90 mm) longer than short front
end vehicle. Short front end design has a character line (arrow) on upper
wing. See Fig. 1 . The transaxle mounts on these vehicles have also been
modified (using pendulum support). From January 1996, drive to the right
side drive axle is via an exposed flange shaft.
NOTE:
In the following procedures, letters and numbers in parenthesis are shown in
illustrations.
NOTE:
When battery is disconnected, vehicle computer and memory systems may
lose memory data. Driveability problems may exist until computer systems
have completed a relearn cycle.
CAUTION:
Radio/cassette or radio/CD player is equipped with an anti-theft protection
circuit. Whenever battery is disconnected, radio will go into anti-theft mode.
When battery is reconnected, radio will display CODE, and will be
inoperative until proper code number is entered. Obtain security code before
disconnecting battery.
Removal & Installation
1. Remove battery covering. With the ignition switched off, disconnect the battery ground strap (in
engine compartment and if installed, under driver's side). Remove charge air cooler from lock carrier
(arrows) if installed. See Fig. 2 . Remove radiator grille with trim frame and tilt out radiator and lock
carrier toward front.
2.
NOTE:
The torsion bars are relieved when vehicle is raised.
Loosen hexagon bolt for drive axle/wheel hub. Raise and support vehicle. Remove left front wheel.
Remove hexagon bolt for drive axle/wheel hub. Using a tape measure, record distance from nut face
to end of torsion bar threaded rod (a). See Fig. 3 .
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
3. Relieve tension on torsion bar with Special Socket (3257). See Fig. 4 . Remove bolts (1) and pull
radiator out in direction of arrow. See Fig. 5 . Pull upper White connector off transaxle vehicle speed
sensor. Remove upper engine/transaxle connecting bolt.
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© 2004 Mitchell Repair Information Company, LLC.
2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
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© 2004 Mitchell Repair Information Company, LLC.
2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 1: Identifying Difference In Long & Short Front End Design
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Fig. 2: Removing Charge Air Cooler From Lock Carrier
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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© 2004 Mitchell Repair Information Company, LLC.
2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 3: Measuring Distance From Nut To End Of Torsion Bar Rod
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 4: Relieving Torsion Bar Tension
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 5: Pulling Out Radiator Toward Front Of Vehicle
Courtesy of VOLKSWAGEN UNITED STATES, INC.
4.
NOTE:
Mark position of engine/transaxle connecting bolts before removal and
only use bolts of same length when replacing.
Remove noise insulation tray. Pull electrical connections off transaxle at valve body (1), vehicle speed
sensor (2) and multifunction TR switch (3). See Fig. 6 . Remove multifunction TR switch cable and
holder from transaxle and position to one side. Remove starter. Unbolt drive axles from transaxle
flange shafts. Raise right drive axle and secure out of the way.
5. Unbolt flanged shaft bearing (A) from transaxle mount (B) at arrow. Pull right hand flange shaft (C)
out from intermediate shaft (D). See Fig. 7 . Detach front exhaust pipe at exhaust manifold. Remove
bolts (arrows) for cover plate. See Fig. 8 .
6. Remove nut (arrow) from torque converter. Rotate torque converter to remove additional nuts (2). See
Fig. 9 . Separate left hand wheel bearing housing/lower swivel joint bolted connection. See Fig. 10 .
Always replace bolts. Remove bolt for left hand shock absorber/stabilizer bar coupling rod. Push left
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
hand shock absorber together. Remove auxiliary heater end pipe, if installed.
Fig. 6: Disconnecting Wiring Connections On Transaxle
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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© 2004 Mitchell Repair Information Company, LLC.
2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 7: Removing Flanged Shaft Bearing From Transaxle
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 8: Removing Cover Plate Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 9: Removing Torque Converter Nut
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 10: Removing Wheel Bearing Housing/Lower Swivel Joint Bolt
Courtesy of VOLKSWAGEN UNITED STATES, INC.
7.
NOTE:
Engine Support (3227) may also be used to support engine on some
vehicles.
Install Support Device (3184) to support engine/transaxle assembly. Install Engine Support (3227) to
engine block, as necessary. See Fig. 11 . Hook Auxiliary Support (3184/1) for Support Device (3184)
in cross panel (arrow). See Fig. 12 . If necessary, remove wiring harnesses and pipes from cross panel.
8. Install Support Device (3184) into Auxiliary Support (3184/1) and into subframe (A). Screw spindle
(C) into hole on engine mount. Align support device so that the slide (B) is resting against the right
hand tube (arrow). Secure support device to subframe (A) and to Auxiliary Support (3184/1) by
tightening the angle plates. Relieve subframe load by raising engine/transaxle using spindle (C). See
Fig. 13 .
9. Remove pendulum support by removing bolts (A and B). See Fig. 14 . Unbolt transaxle mount from
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
body (arrow 1). Carefully lower engine using support device spindle. Unbolt bearing block from
transaxle (arrow 2). See Fig. 15 .
Fig. 11: Installing Engine Support
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 12: Attaching Auxiliary Support
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 13: Raising Engine/Transaxle Assembly Using Support Device & Auxiliary Support
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 14: Removing Pendulum Support
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 15: Unbolting Transaxle Mount & Bearing Block
Courtesy of VOLKSWAGEN UNITED STATES, INC.
10. Carefully swivel engine/transaxle forward and lower, thereby ensuring that the selector lever cable,
multifunction TR switch and drive axles are not damaged. To swivel forward, turn spindle (D) to the
left. To swivel back, turn spindle (D) to the right. See Fig. 13 . Ensure that the selector lever cable
does not become tightened. Unclip selector lever cable securing clips and detach selector lever cable.
Clamp off ATF cooler hoses and detach at ATF cooler.
11. Tilt engine/transaxle further forward and lower. Ensure sufficient clearance exists between engine and
vehicle longitudinal member. Loosen alternator and remove tensioning arm from engine, if necessary.
Remove left hand drive axle, ensuring multifunction TR switch is not damaged.
12.
NOTE:
The support element (C) can be used with the corresponding hole
(arrow) in the adjustment plate to remove the transaxle in cases where
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
the engine has a metal oil sump. Once the torque converter cover has
been removed, the support element (C) should be bolted tight to the
torque converter housing. See Fig. 16 .
Set up Transaxle Support (3282). The Transaxle Support (3282) is set up with the Adjustment Plate
(3282/22A) for removal of transaxle. Bolt on Support Elements (A), as shown in illustration of
adjustment plate. See Fig. 16 and Fig. 17 . Move Transaxle Jack (VAG 1383A) with Transaxle Mount
(3282) under the transaxle and support transaxle. The arrow (B) on the adjustment plate points in
direction of normal travel. Secure Transaxle Support (3282) with drilled plate to the pendulum
support bushing (arrow). See Fig. 18 .
13. Remove lower engine/transaxle connecting bolts. Press transaxle off engine, while pressing torque
converter out of drive plate. Press torque converter against ATF pump. Lower transaxle slightly.
Swivel transaxle and carefully lower. Secure torque converter to prevent it from falling out.
14. To install transaxle, reverse removal procedure. When installing the torque converter, ensure that both
drive pins engage in the ATF pump inner wheel recesses. Always replace self locking nuts and bolts.
Before installing, ensure that the dowel sleeves are correctly located.
15. Before installing starter mounting bushing, check for wear and replace, if necessary. Before installing
pendulum support bushing, check for wear and replace, if necessary. While swinging transaxle
inward, install both drive axles in the flanged shaft and drive flange.
Fig. 16: Identifying Adjustment Plate Direction
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© 2004 Mitchell Repair Information Company, LLC.
2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Fig. 17: Installing Adjustment Plate To Transaxle Support
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 18: Securing Transaxle Support To Pendulum Support
Courtesy of VOLKSWAGEN UNITED STATES, INC.
16.
WARNING:
Do not remove Support Device (3184) until the bolts securing the left
hand bearing bracket have been securely tightened.
Before lifting engine/transaxle, tighten bolts (arrows 2) to specification. After lifting engine/transaxle,
tighten nuts (arrow 1) to specification. See Fig. 15 . Tighten all nuts and bolts to specification. See
TORQUE SPECIFICATIONS .
17. Adjust torsion bar threaded rod distance. See Fig. 3 . Check selector lever cable adjustment, and
adjust as necessary. Check and top off ATF level. See SERVICING - EUROVAN article.
VEHICLES WITH LONG FRONT END
Removal & Installation
NOTE:
In the following procedures, letters and numbers in parenthesis are shown in
illustrations.
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© 2004 Mitchell Repair Information Company, LLC.
2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
NOTE:
When battery is disconnected, vehicle computer and memory systems may
lose memory data. Driveability problems may exist until computer systems
have completed a relearn cycle.
CAUTION:
Radio/cassette or radio/CD player is equipped with an anti-theft protection
circuit. Whenever battery is disconnected, radio will go into anti-theft mode.
When battery is reconnected, radio will display CODE, and will be
inoperative until proper code number is entered. Obtain security code before
disconnecting battery.
1. Remove battery covering. With the ignition switched off, disconnect the battery ground strap (in
engine compartment and if installed, under driver's side). Loosen hex bolt for drive axle/wheel hub.
Raise and support vehicle. Remove left front wheel. Remove hex bolt for drive axle/wheel hub.
2.
NOTE:
Mark position of engine/transaxle connecting bolts before removal and
only use bolts of same length when replacing.
NOTE:
3.
4.
5.
6.
The torsion bars are relieved when vehicle is raised.
Remove upper engine/transaxle connecting bolts. Pull upper connector off transaxle (transaxle vehicle
speed sensor). Using a tape measure, record distance from nut face to end of torsion bar threaded rod
(a). See Fig. 3 . Relieve tension on torsion bar with Special Socket (3257). See Fig. 4 . Remove noise
insulation tray.
Remove electrical connections (arrows) at transaxle. See Fig. 19 . Pull connector off speedometer
sender. Remove starter. Unbolt drive axles from transaxle flange shafts. Raise right drive axle and
secure out of the way. Remove transaxle carrier (A) bolts (arrows) for right hand flanged shaft
bearing. Pull out flanged shaft (B). See Fig. 20 .
Detach front exhaust pipe at exhaust manifold. Remove bolts (arrows) for cover plate. See Fig. 8 .
Remove nut (arrow) from torque converter. Rotate torque converter to remove additional nuts (2). See
Fig. 9 .
Remove pendulum support by removing bolts (A and B). See Fig. 14 . Using appropriate socket (1),
separate left hand wheel bearing housing/lower swivel joint bolted connection. See Fig. 21 . Always
replace bolts.
Remove bolt for left hand shock absorber/stabilizer bar coupling rod. Press drive axle out of wheel
bearing housing. Push left hand shock absorber together. Remove left hand drive axle, ensuring
multifunction TR switch is not damaged. Remove auxiliary heater end pipe, if installed.
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 19: Disconnecting Wiring Connections At Transaxle
Courtesy of VOLKSWAGEN UNITED STATES, INC.
4 января 2005 г. 1:03:47
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 20: Removing Transaxle Carrier For Right Hand Flanged Shaft Bearing
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 21: Separating Left Hand Wheel Bearing Housing From Lower Swivel Joint
Courtesy of VOLKSWAGEN UNITED STATES, INC.
7. Remove engine/transaxle securing bolt (arrow). See Fig. 22 . Install Retainer (3407) to engine. See
Fig. 23 . Install Support Device (10-222A) in conjunction with Supports (10-222 A/6). Attach Hook
(10-222 A/2) and Auxiliary Hook (10-222 A/7) in left hand support spindle. See Fig. 24 . Attach
Auxiliary Hook (10-222 A/7) in Retainer (3407). See Fig. 23 . Attach Hook (10-222 A/2) in right
hand support spindle and on engine. Tighten engine/transaxle assembly on the spindles.
8. Unclip selector lever cable securing clips and detach selector lever cable. Clamp off ATF cooler hoses
and detach at ATF cooler.
9.
NOTE:
The support element (C) can be used with the corresponding hole
(arrow) in the adjustment plate to remove the transaxle in cases where
the engine has a metal oil sump. Once the torque converter cover has
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© 2004 Mitchell Repair Information Company, LLC.
2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
been removed, the support element (C) should be bolted tight to the
torque converter housing. See Fig. 16 .
Set up Transaxle Support (3282). The Transaxle Support (3282) is set up with the Adjustment Plate
(3282/22A) for removal of transaxle. Bolt on Support Elements (A), as shown in illustration of
adjustment plate. See Fig. 16 and Fig. 17 .
10. Move Transaxle Jack (VAG 1383A) with Transaxle Mount (3282) under the transaxle and support
transaxle. The arrow (B) on the adjustment plate points in direction of normal travel. Secure Transaxle
Support (3282) with drilled plate to the pendulum support bushing (arrow). See Fig. 18 .
11.
NOTE:
To remove securing nuts, use step ladder as necessary.
Unbolt transaxle mount from body (arrow 1). See Fig. 15 . Carefully lower engine/transaxle assembly
via spindles of support device and, at the same time, via the Transaxle Jack (VAG 1383A). Unbolt
bearing block with transaxle mount from transaxle (arrow 2). See Fig. 15 .
12. Remove lower engine/transaxle connecting bolts. Press transaxle off engine, while pressing torque
converter out of drive plate. Press torque converter against ATF pump. Swivel transaxle and carefully
lower. Secure torque converter to prevent it from falling out.
13. To install transaxle, reverse removal procedure. When installing the torque converter, ensure that both
drive pins engage in the ATF pump inner wheel recesses. Always replace self locking nuts and bolts.
Before installing, ensure that the dowel sleeves are correctly located.
14. Before installing starter mount bushing, check for wear and replace, if necessary. Before installing
pendulum support bushing, check for wear and replace, if necessary. Install left hand drive axle.
15.
WARNING: Do not remove Support Device (10-222A) until the bolts securing the
left and right assembly mounts have been securely tightened.
Before lifting engine/transaxle, tighten bolts (arrows 2) to specification. After lifting engine/transaxle,
tighten nuts (arrow 1) to specification. See Fig. 15 . First tighten transaxle carrier (A) bolts on engine
to specification, then tighten flanged shaft (B) bearing bolts to specification. See Fig. 20 . Tighten all
nuts and bolts to specification. See TORQUE SPECIFICATIONS .
16. Adjust torsion bar threaded rod distance. See Fig. 3 . Check selector lever cable adjustment, and
adjust as necessary. Check and top off ATF level. See SERVICING - EUROVAN article.
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 22: Removing Engine/Transaxle Securing Bolt
Courtesy of VOLKSWAGEN UNITED STATES, INC.
4 января 2005 г. 1:03:48
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 23: Installing Retainer To Engine
Courtesy of VOLKSWAGEN UNITED STATES, INC.
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2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Fig. 24: Installing Support Device With Adapters & Hooks
Courtesy of VOLKSWAGEN UNITED STATES, INC.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Cover Plate-To-Transaxle Bolt
Drive Axle-To-Wheel Hub Bolt
Ft. Lbs. (N.m)
11 (15)
(1)
111 (150)
Left Hand Transaxle Mount
Bolt
(2)
Nut
Lower Control Arm-To-Wheel Bearing Housing Bolt
37 (50)
41 (55)
(3)
Torque Converter-To-Drive Plate Nut
Transaxle Carrier Flanged Shaft Bearing-To-Engine Bolt
66 (90)
44 (60)
(4)
30 (40)
Transaxle Carrier Flanged Shaft Bearing-To-Flange Bolt
(4)
18 (25)
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© 2004 Mitchell Repair Information Company, LLC.
2003 Volkswagen EuroVan MV
REMOVAL & INSTALLATION - A/T (01P)
Transaxle Mounting-To-Bearing Housing Bolt
Transaxle Mounting-To-Engine Bolt
Transaxle-To-Engine Bolt
M 8 Bolt
M 10 Bolt
M 12 Bolt
18 (25)
30 (40)
17 (23)
44 (60)
59 (80)
(1)
Tighten bolt to specification plus an additional 90 degrees.
(2)
Tighten bolt to specification plus an additional 90 degrees. See Fig. 15 .
(3)
Tighten bolt to specification plus an additional 90 degrees. See Fig. 10 .
(4)
For bolt locations, see Fig. 20 .
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