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How to remove the torque converter

Customer Question
how to remove the torque converter
Submitted: 7 years ago.Category: VW
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Answered in 2 hours by:
1/23/2010
VW Mechanic: Tim's Auto Repair, mechanic replied 7 years ago
Tim's Auto Repair
Category: VW
Satisfied Customers: 16,162
Experience: Have owned a repair shop for 25 yrs.
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hi

you will need to remove the transaxle to remove the torque converter

thanks

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Volkswagen Cars 2000-05

Transaxle Removal & Installation

 

  1. Disconnect the battery cables.
  2. Remove the battery.
  3. Remove all electrical connections and vacuum lines from the transaxle.
  4. On 6 cylinder models remove the multi-function transaxle range switch.
  5. Position the selector lever to the Park position.
  6. Detach the selector lever cable.
  7. Remove the selector lever cover. Remove the selector lever cable circlip. Remove the cable.
  8. Support the engine from the top with the appropriate brace.
  9. Remove the power steering hose support bracket.
  10. On vehicles equipped with the VR-6, remove the electrical connector from the cooling fan.
  11. Remove the bolt from the front engine mount.
  12. Detach the mount from the engine block by removing the mounting bolts.
  13. Remove the coolant recovery tank.
  14. Completely remove the left rear engine mount.
  15. Remove the transmission mounting bolts at the top only.
  16. Remove the protective shield from the automatic transmission fluid (ATF) pan.
  17. On VR-6 engines, remove the right side accessory drive belt shield.
  18. Remove the torque converter mounting nuts.
  19. Remove the vibration damper from the 6 cylinder engine.
  20. Detach the drive axles from the transaxle.
  21. Support the right side axle.
  22. Remove the left front wheel.
  23. Position the steering wheel to full right lock.
  24. Matchmark the position of the ball joint in relation to the lower control arm.
  25. Remove the ball joint mounting bolts.
  26. Pull the ball joint from the control arm.



NOTE The left hand drive axle must be removed if the vehicle is equipped triple-roller type CV joints.

  1. Support the transmission from the under side using a special transmission jack or the proper jack adapter.
  2. Remove the bolts from the lower engine/transmission mounting bolts.
  3. Pivot the engine forward using a suitable jack/support.
  4. Pull the engine from the transmission.
  5. Lower the engine with the support jack.
  6. Lower the transaxle. You may have to re-position the transaxle several times to ease removal.



NOTE Be sure to secure the torque converter to the transaxle.

To install:

  1. Install the transaxle assemble in the reverse order of removal. Tighten the fasteners to the following specifications.
  2. The front engine mount should be secured at a tighten of 44 ft. lbs. (60 Nm).
  3. When installing the drive axle to the transaxle flange tighten the bolts to 33 ft. lbs. (45 Nm).
  4. The torque converter to flex plate (drive plate) should be tightened to 44 ft. lbs. (60 Nm).
  5. After installing the left motor mount, tighten the mounting bolt(s) to 44 ft. lbs. (60 Nm).
  6. Ball joint to control arm nut(s) should be tightened to 26 ft. lbs. (35 Nm).

 

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Remove or disconnect:

    Battery and the speedometer drive and plug the hole in the transaxle. On the Golf and Jetta models, front axle nuts.



CAUTION When loosening or tightening an axle nut, be sure the vehicle is on the ground. Axle nut torque is high enough that attempting to loosen it may cause the vehicle to fall.


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 16V engine, the idle stabilizer valve must be removed to attach the tool. Do not try to support the engine from below. Driver's side rear transaxle mount and support bracket. On the Golf and Jetta models, front mount bolts from the transaxle and from the body and mount as a complete assembly. Selector and accelerator cables from the transaxle lever but leave them attached to the bracket. Remove the bracket assembly to save the adjustment. Halfshafts from the drive flanges. On the Golf and Jetta models, the shafts must be removed, which may require separating the ball joints from the wheel bearing housing to gain the necessary clearance. Remove the ball joint clamping bolt. Heat shield and brackets and remove the starter. On the Cabrio models, the front mount comes off with the starter. Torque converter-to-flywheel bolts, turning the engine as needed. Remaining transaxle mounts, on the Golf and Jetta models, the subframe bolts and allow the subframe to hang free.

  1. 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.
  2. Carefully lower the transaxle from the vehicle.

 

To install:

  1. When reinstalling, be sure the torque converter is fully seated on the pump shaft splines. The converter should be recessed into the bell housing and turn by hand. Keep checking that it still turns while drawing the engine and transaxle together with the bolts.
  2. Install or connect:

    Engine-to-transaxle bolts. Bolts: 55 ft. lbs. (75 Nm). All mount and subframe bolts before tightening any on them. Tighten the bolts starting at the rear and work forward. Smaller bolts: 25 ft. lbs. (34 Nm) and larger bolts: 58 ft. lbs. (80 Nm). Remove the lifting equipment when all mounts are installed. Torque converter-to-flywheel bolts. Bolts: 26 ft. lbs. (35 Nm). Starter. Bolts: 14 ft. lbs. (20 Nm). Heat shields.



NOTE If the halfshafts were removed, be sure the splines are clean and apply a thread-locking compound to the splines before sliding it into the hub.


Halfshafts to the drive flanges. Bolts: 37 ft. lbs. (50 Nm). Install new axle nuts but do not fully tighten them until the vehicle is on the ground. If removed, fit the ball joints to the control arm. Clamping bolt: 37 ft. lbs. (50 Nm). Shift linkage. Adjust as required.

  1. When assembly is complete and the vehicle is on its wheels, tighten the axle nuts to 195 ft. lbs. (265 Nm).

 

  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.




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

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

image

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

image

FIG : The engine must be supported using a suitable support tool and sling

image

FIG : The bolt location and torque for the A4 V6

image

FIG : The bolt location and torque for the Passat V6

image

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.


  2. Torque converter to drive plate: 63 ft. lbs. (85 Nm)
  3. Install the halfshafts. DO NOT tighten the outer mounting bolt until the vehicle is resting on the ground.
  4. The balance of assembly is in reverse order of removal noting the following component torque.


  5. 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)
  6. Upon assembly, check the final drive oil level and the transmission fluid level and top off as necessary.

  1. Remove or disconnect:
    CAUTION When loosening or tightening an axle nut, be sure the vehicle is on the ground. Axle nut torque is high enough that attempting to loosen it may cause the vehicle to fall.


    Battery and the speedometer drive and plug the hole in the transaxle. On the Golf and Jetta models, front axle nuts.


    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 16V engine, the idle stabilizer valve must be removed to attach the tool. Do not try to support the engine from below. Driver's side rear transaxle mount and support bracket. On the Golf and Jetta models, front mount bolts from the transaxle and from the body and mount as a complete assembly. Selector and accelerator cables from the transaxle lever but leave them attached to the bracket. Remove the bracket assembly to save the adjustment. Halfshafts from the drive flanges. On the Golf and Jetta models, the shafts must be removed, which may require separating the ball joints from the wheel bearing housing to gain the necessary clearance. Remove the ball joint clamping bolt. Heat shield and brackets and remove the starter. On the Cabrio models, the front mount comes off with the starter. Torque converter-to-flywheel bolts, turning the engine as needed. Remaining transaxle mounts, on the Golf and Jetta models, the sub-frame bolts and allow the sub-frame to hang free.
  2. 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.
  3. Carefully lower the transaxle from the vehicle.

To install:

  1. When reinstalling, be sure the torque converter is fully seated on the pump shaft splines. The converter should be recessed into the bell housing and turn by hand. Keep checking that it still turns while drawing the engine and transaxle together with the bolts.
  2. Install or connect:
    NOTE If the halfshafts were removed, be sure the splines are clean and apply a thread-locking compound to the splines before sliding it into the hub.


    Engine-to-transaxle bolts. Bolts: 55 ft. lbs. (75 Nm). All mount and sub-frame bolts before tightening any on them. Tighten the bolts starting at the rear and work forward. Smaller bolts: 25 ft. lbs. (34 Nm) and larger bolts: 58 ft. lbs. (80 Nm). Remove the lifting equipment when all mounts are installed. Torque converter-to-flywheel bolts. Bolts: 271 inch lbs. (35 Nm). Starter. Bolts: 14 ft. lbs. (20 Nm). Heat shields.


    Halfshafts to the drive flanges. Bolts: 37 ft. lbs. (50 Nm). Install new axle nuts but do not fully tighten them until the vehicle is on the ground. If removed, fit the ball joints to the control arm. Clamping bolt: 37 ft. lbs. (50 Nm). Shift linkage. Adjust as required.
  3. When assembly is complete and the vehicle is on its wheels, tighten the axle nuts to 195 ft. lbs. (265 Nm).

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect:

    Engine cover and under cover. Negative, then the positive battery cable. Power steering reservoir from the battery tray and position it aside leaving the hoses attached. Battery and tray. Air cleaner and intake air hose. Connector for the reverse light switch and VSS. Electrical connections at the transaxle. Selector lever at the transaxle. Ground cable from the upper transaxle-to-engine mounting bolt. Starter. After clamping off the ATF cooler lines at the transaxle, the cooler. Upper transaxle-to-engine mounting bolts.
  3. Install a suitable engine support fixture and slightly lift the engine.
  4. Remove or disconnect:

    Left front wheel. All engine under covers Halfshafts at the transaxle. Right halfshaft and position it out of the way. Left halfshaft. Pendulum support. If necessary, right side cooling fan. Cap for the torque converter nut cover. 3 torque converter nuts. Left engine/transaxle mount. Transaxle jack, then support the weight of the transaxle. Lower transaxle-to-engine mounting bolts.
  5. Separate the transaxle from the engine while pushing the torque converter out of the driveplate.
  6. Push the torque converter against the ATF pump.
  7. While lowering the transaxle, guide the power steering hoses past the transaxle.
  8. Secure the torque converter to prevent it from falling out.

To install:

  1. When reinstalling, be sure the torque converter is fully seated on the pump shaft splines. The converter should be recessed into the bell housing and turn by hand.
  2. Install or connect:

    Transaxle into the vehicle. Lower transaxle-to-engine mounting bolts. Left engine/transaxle mount, then remove the transaxle jack. Torque converter-to-flexplate mounting nuts. Nuts: 44 ft. lbs. (60 Nm). Torque converter nut cap. Pendulum support. Left halfshaft. Right halfshaft. Flange bolts: 30 ft. lbs. (40 Nm). Wheel. Lug bolts: 89 ft. lbs. (120 Nm). Upper transaxle-to-engine mounting bolts. ATF cooler using new O-rings and remove the clamps. Starter. Ground cable at the upper transaxle mounting bolt. Transaxle selector lever. Electrical connections at the transaxle. Engine support fixture. Intake air hose and air cleaner assembly. Battery tray and battery. Power steering reservoir to the battery. Battery cables. All covers that were removed.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect:

    Battery. Wiring from the transaxle. Upper engine-to-transaxle bolts. 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. The idle stabilizer valve must be removed to attach the tool. Do not try to support the engine from below. Shift cable. Hoses at the transaxle cooler. Starter and the engine's left and right mounts. Skid plate Halfshafts from the drive flanges. Hang them from the body with wire. Torque converter plate and turn the engine as needed to remove the torque converter-to-flywheel bolts. Remaining transaxle mounts and lower the hoist slightly.
  3. 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.
  4. Carefully lower the transaxle out of the vehicle.

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 the 12mm bolts to 59 ft. lbs. (80 Nm), the 10mm bolts to 44 ft. lbs. (60 Nm).
  2. Install or connect:

    Transaxle mounts. Bolts: 44 ft. lbs. (60 Nm). Left side bracket-to-transaxle bolts: 18 ft. lbs. (25 Nm). Torque converter bolts: 44 ft. lbs. (60 Nm). Halfshafts. Bolts: 33 ft. lbs. (45 Nm). Shift linkage. Adjust as required.
  3. Install the remaining parts and check the fluid level in the transaxle.

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Satisfied Customers: 16,162
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