VW Passat & Audi A4 1990-2000

Automatic Transaxle Assembly

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REMOVAL & INSTALLATION
1990-93 Passat models
  1. If equipped with electronically theft-protected radio, obtain the security code before disconnecting the battery.
  2.  
  3. Remove the battery and disconnect the wiring from the transaxle.
  4.  
  5. Remove the upper engine-to-transaxle bolts.
  6.  
  7. Raise and safely support the vehicle and remove the front wheels. Connect the engine sling tool VW-10-222A or equivalent, to the cylinder head and just take the weight of the engine off the mounts. On Passat, the idle stabilizer valve must be removed to attach the tool. Do NOT try to support the engine from below.
  8.  
  9. Put the shifter in P and disconnect the shift cable.
  10.  
  11. Clamp and remove the hoses at the transaxle cooler.
  12.  
  13. Remove the starter and the left and right engine mounts.
  14.  
  15. Remove the skid plate and disconnect the halfshafts from the drive flanges. Hang them from the body with wire.
  16.  
  17. Remove the torque converter plate and turn the engine as needed to remove the torque converter-to-flywheel bolts.
  18.  
  19. Remove the remaining transaxle mounts and lower the hoist slightly.
  20.  
  21. Support the transaxle with a jack and remove the remaining engine-to-transaxle bolts.
  22.  


WARNING
Be careful to secure the torque converter so it does not fall out of the transaxle.

  1. Carefully lower the transaxle out of the vehicle.
  2.  



Click image to see an enlarged view

Fig. The engine is supported during transaxle removal using Tool No. 10-222A or its equivalent

To install:

  1. Fit the transaxle into the vehicle and make sure the guide pins fit properly between the engine and transaxle. Install the bolts and torque as follows:
  2.  

Transaxle-to-engine mounting bolts:



10mm bolts: 44 ft. lbs. (60 Nm).
 
12mm bolts: 59 ft. lbs. (80 Nm)
 

  1. The balance of assembly is in reverse order or removal noting the following.
  2.  
  3. Install the transaxle mounts, then the left side and front brackets and torque to:
  4.  
  5. Transaxle mount bolts: 44 ft. lbs. (60 Nm).
  6.  
  7. Bracket-to-transaxle, left: 18 ft. lbs. (25 Nm).
  8.  
  9. Bracket-to-transaxle, front: 44 ft. lbs. (60 Nm)
  10.  
  11. Torque converter bolts: 44 ft. lbs. (60 Nm).
  12.  
  13. Halfshafts: 33 ft. lbs. (45 Nm).
  14.  
  15. Connect and adjust the shift linkage as required.
  16.  
  17. Check the fluid level and top off as necessary.
  18.  

1995-97 Passat models
  1. If equipped with electronically theft-protected radio, obtain the security code before disconnecting the battery.
  2.  
  3. Remove the battery and disconnect the wiring from the transaxle.
  4.  
  5. Remove the upper engine-to-transaxle bolts.
  6.  
  7. Raise and safely support the vehicle and remove the front wheels. Connect an engine sling tool, such as Tool No. VW-10-222A and related attachments, to the cylinder head and just take the weight of the engine off the mounts. The idle stabilizer valve must be removed to attach the tool. Do NOT try to support the engine from below.
  8.  
  9. Put the shifter in P (park) and disconnect the shift cable.
  10.  
  11. Clamp and remove the hoses at the transaxle cooler.
  12.  
  13. Remove the starter and the left and right engine mounts.
  14.  
  15. Remove the skid plate and disconnect the halfshafts from the drive flanges. Support them from the body with wire.
  16.  
  17. Remove the torque converter plate and turn the engine as needed to remove the torque converter-to-flywheel bolts.
  18.  
  19. Remove the remaining transaxle mounts and lower the hoist slightly.
  20.  
  21. Support the transaxle with a jack and remove the remaining engine-to-transaxle bolts. Be careful to secure the torque converter so it does not fall out of the transaxle.
  22.  
  23. Carefully lower the transaxle out of the vehicle.
  24.  



Click image to see an enlarged view

Fig. The engine is supported using a suitable support tool and attachments

To install:

  1. Fit the transaxle into the vehicle and be sure the guide pins fit properly between the engine and transaxle. Install the bolts and tighten as follows:
  2.  

Transaxle-to-engine bolts:



10mm bolts: 44 ft. lbs. (60 Nm)
 
12mm bolts: 59 ft. lbs. (80 Nm), the.
 

  1. Install the transaxle mounts and tighten the bolts:
  2.  
  3. Mount-to-transaxle: 44 ft. lbs. (60 Nm).
  4.  
  5. Tighten the left side bracket-to-transaxle bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the torque converter bolts and tighten them to 44 ft. lbs. (60 Nm).
  8.  
  9. Connect the halfshafts and tighten the bolts to 33 ft. lbs. (45 Nm).
  10.  
  11. Connect and adjust the shift linkage as required.
  12.  
  13. The balance of assembly is in reverse order of removal.
  14.  
  15. Check the fluid level and top off as necessary.
  16.  

A4 & 1998-Passat Models
  1. Note the radio security code.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine trim covers.
  6.  
  7. 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.
  8.  
  9. 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.
  10.  
  11. Loosen the outer axle mounting bolts and front wheel lug bolts, BEFORE lifting and supporting the vehicle.
  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Remove the front wheels.
  16.  
  17. Remove the lower engine shield.
  18.  
  19. Remove the axle noise insulation brackets and trays and the right axle protective plate.
  20.  
  21. Remove the halfshafts.
  22.  
  23. Disconnect the electrical connectors for the multi-function switch, transmission wiring, and the speedometer speed sensor.
  24.  


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.  
  3. Remove the front half of the exhaust system making sure to disconnect any electrical connectors as necessary.
  4.  
  5. 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.
  6.  
  7. Place a suitable drain pan under the transmission and remove the ATF cooling lines from the transmission and seal the lines and the transmission.
  8.  
  9. Remove the gear selector cable from the selector shaft.
  10.  
  11. Remove the starter motor allowing access to the torque converter mounting bolts.
  12.  
  13. Remove the torque converter mounting bolts rotating the engine as necessary to access the bolts through the starter drive gear opening.
  14.  
  15. Remove the lower engine-to-transmission mounting bolts.
  16.  
  17. Support the transmission with a suitable transmission jack.
  18.  
  19. Remove the left and right support mounts and support plates.
  20.  
  21. Remove the multi-function switch and cover its installation hole.
  22.  
  23. 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).
  24.  
  25. Lower the transmission jack slightly to gain access to the top transmission-to-engine mounting bolts and remove the bolts.
  26.  
  27. 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.
  28.  
  29. Pivot the rear of the transmission downward between the subframe and the underbody, then lower the transmission from the engine.
  30.  



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

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



Click image to see an enlarged view

Fig. The bolt location and torque for the A4 V6



Click image to see an enlarged view

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.  
  3. Install the upper transmission-to-engine mounting bolts and torque to 48 ft. lbs. (65 Nm).
  4.  
  5. Raise the transmission and engine and install the subframe making sure to align the matchmarks made during disassembly.
  6.  
  7. Torque the subframe as follows:
  8.  

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.  
  3. Install the lower transmission-to-engine bolts and torque as follows:
  4.  

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.
  2.  
  3. Torque converter to drive plate: 63 ft. lbs. (85 Nm)
  4.  
  5. Install the halfshafts. DO NOT tighten the outer mounting bolt until the vehicle is resting on the ground.
  6.  
  7. The balance of assembly is in reverse order of removal noting the following component torque.
  8.  
  9. ATF line-to-transmission: 15ft. lbs. (20 Nm)
  10.  
  11. Bracket for ATF line: 84 inch lbs. (10 Nm)
  12.  
  13. Halfshaft-to-transmission: 59 ft. lbs. (80 Nm)
  14.  
  15. Wheel bolts to wheel hub: 89ft. lbs. (120 Nm)
  16.  
  17. Upon assembly, check the final drive oil level and the transmission fluid level and top off as necessary.
  18.  

ADJUSTMENTS
Throttle Linkage
1990-93 passat models
  1. With the engine warm and the gear selector in P , loosen the adjusting nut and disconnect the accelerator pedal cable from the transaxle.
  2.  
  3. On the intake plenum, loosen the nuts on the cable bracket and move the sleeve away from the throttle to take up any play. The throttle must remain closed.
  4.  
  5. Turn the nut on the throttle side of the bracket up to the bracket and tighten the other nut against the bracket. Be sure the throttle is still against its stop.
  6.  
  7. Reconnect the cable to the transaxle and have an assistant push the gas pedal to the floor.
  8.  
  9. Push the transaxle lever against the stop and turn the adjusting nut to remove all slack from the cable. Tighten the locknut, release the pedal and push it again to check adjustment.
  10.  

 
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