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Go Back   TDIClub Forums > TDI Model Specific Discussions Areas > VW MKIV-A4 TDIs (VE and PD)

VW MKIV-A4 TDIs (VE and PD) This is a general discussion about A4/MkIV Jetta (99.5-~2005), Golf(99.5-2006), and New Beetle(98-2006). Both VE and PD engines are covered here.

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Old April 22nd, 2012, 19:05   #1
spartan
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Default Trouble Remove Transmission on 05 TDI

Hello, I am right in the middle of swapping my 09A automatic for an 02J 5 speed manual. I have run into a bit of a hurdle while trying to get the auto out of the car. It seems that I don't have enough room to remove the transmission to engine bolts, as my triple square socket seems to be taking up most of the space. I feel like a total goof since I am assuming this should be easy since all any of the instructions say is "remove engine to trans bolts" and that's it. I have included some photos so that hopefully I can get some insight as to what other tool I need or how I should go about getting these things out.









Also, while removing my dogbone mount, I noticed that one of the bolt heads in the subframe was broken off leaving only a rusted stud. Well that took me an hour to get off, and now I just have the stud taunting me. What would be the best course of action to remove it? I would prefer not to helicoil if I can help it.

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Old April 23rd, 2012, 11:21   #2
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Last first: For the busted off bolt on for the dogbone mount I would soak in PB Blaster for a couple of days (douse it a couple of times a day) and after the first dousing, I would take a BFH (a big hammer) and hit the top of the busted bolt a few times, as if driving a nail. The idea is to loosen the threads. Don't his so hard as to damage the threads. soak in PB Blaster after hammering. After soaking and tappping, take a big pair of vice grips or a pipe wrhench and turn the bolt bit out. It will come out.

For the auto transaxle tripple squares, '05 was a split model year, with both the A4 and A5 offered. Which is yours? I suspect the shop manual will state to use a special purpose VW tool to get to them. If you had a tripple square that would accept a wrench you'd be in business. I can check my Bentley tonight and see if any special tool is called for. I have two bentleys--One for the A4 and one for the A5.

A couple of them look like you could use a 1/2 inch drive universal joint on a long extension with your tripple square bit. The other two, no way.

--Nate
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Old April 23rd, 2012, 12:31   #3
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For trans axle triple squares I used and 1/2 wrench with a triple square bit cut down, to give me some room. As for the broken stud, as PDJetta stated soak it with PB Blaster for a day, the stuff doesn't work instantly, and if you have a torch heat the hell out of it and then use the vice grips to break it free.

HTH

James.
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Old April 23rd, 2012, 13:16   #4
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Old April 23rd, 2012, 13:40   #5
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Thanks for the help, I also ordered a set of stubby triple square bits off amazon, so hopefully I will be able to get these things out with some help from swivels and other parts. I will also look into the socket cap set, I know I could have used those in other jobs, so maybe I will pick those up regardless. Oh and my car is an A4, jetta wagon.

I already started soaking that bolt, but I am going to wait til the transmission is out of the way regardless to try and pull it.

THANKS!
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Old April 23rd, 2012, 16:55   #6
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Quote:
Originally Posted by Redneck Truck View Post
Those are slick. I'll have to get a set!
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Old April 25th, 2012, 08:40   #7
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Quote:
Originally Posted by PDJetta View Post
Last first: For the busted off bolt on for the dogbone mount I would soak in PB Blaster for a couple of days (douse it a couple of times a day)...
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Old June 20th, 2012, 19:27   #8
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What tool or combination of tools did you end up using to get out the 2 bolts on top of the auto tranny. Is that triple square bolt a 14mm? I've been looking for a universal joint triple square socket to fit in that tight space. Where did you buy yours?

thanks

Last edited by grubyuppie; June 20th, 2012 at 22:04.
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Old June 21st, 2012, 17:53   #9
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I bought a set of shorty triple square bits from amazon.com. They were dramatically shorter (.75-1") than the normal sockets. Those and a wobble extension was all that I needed.
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