Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ Engine support bracket 10-222A with supports10-222A/1
• ◆ Gearbox support 3282
• ◆ Alignment plate 3282/18
• ◆ Engine press tool 3300 A
• ◆ Engine/gearbox jack V.A.G 1383 A
• ◆ Torque wrench V.A.G 1332

Removing

• ‒ Loosen nut on left drive shaft.

Note:

Only loosen and tighten drive shaft nuts with vehicle standing on its wheels. (Danger of accident).

• ‒ For vehicles with coded radio obtain radio code.

• ‒ With the ignition switched off disconnect the battery earth strap.

• ‒ Remove battery and console, lay P.A.S. reservoir to one side and secure with wire.
• ‒ → Remove right-hand engine console/sub-frame securing bolt (arrow), first remove cable connector retaining plate -A- if fitted.

• ‒ → Pull off speedometer sender connector (arrow 1) and reverse light connector (arrow 2).
• ‒ Remove protective cap -arrow 3-.
• ‒ Disconnect wiring harness/engine connector (arrow 4).

• ‒ → Remove balance weight -A- and gear selector cable -B- from gear selector lever.
• ‒ Pull gate selector cable off actuating arm/relay lever -C- , to do this lift lug in direction of arrow.

• ‒ → Remove cable support bracket from gearbox (arrows) and tie up, first unclip hose on support bracket if necessary.

• ‒ → Remove slave cylinder and secure to side with wire, do not disconnect pipe.

Note:

Do not depress clutch pedal.

• ‒ Remove starter.

=> Repair group 27; Electrical system

• ‒ Remove earth strap at engine/gearbox upper securing bolt.
• ‒ Remove upper engine/gearbox securing bolts.

• ‒ → Fit support bar 10-222 A together with legs 10-222 A/1 and support engine/gearbox.

Note:

Before fitting the support hooks of the support bar, remove hose and wire connections from engine in the area of the lifting eyes, so that they are not damaged.

• ‒ Take weight of engine/gearbox assembly on the spindles.

• ‒ → If fitted, remove air duct -A- for cooling the propshaft bearing (arrow 1) and pull off from front fan connection.
• ‒ Remove manifold -B- (arrow 2) and push to side.

• ‒ Remove power assisted steering pipe bracket from gearbox.
• ‒ → Remove front console (bolts -A- and -B-).
• ‒ Release front engine mounting (bolt -C-).

• ‒ Remove engine/gearbox securing bolt on right above bevel box.
• ‒ → Remove hexagon bolt -A- from left-hand gearbox assembly mounting -B-.

• ‒ Remove power assisted steering pipes from front engine mounting.

• ‒ → Remove front engine mounting -arrows-.

• ‒ → Remove connecting bolts gearbox mounting to bevel box -arrows A-.
• ‒ Only loosen bolts -arrow B- and -arrow C-.

• ‒ → If fitted cut balance weight mounting (arrows) on assembly carrier off flush using body saw V.A.G 1523. Do not damage assembly carrier.

• ‒ If necessary repair paint work damage as follows:
  Remove grease remains with Nitro thinners L 001 600.
  Apply 2 component acrylic paint (ALN 769 041 with hardener ALZ 009 001).

• ‒ Separate exhaust system behind front exhaust pipe.

=> Repair group 26; Removing and installing parts of exhaust system, four wheel drive.

• ‒ Remove heat shield above catalyst.
• ‒ Secure catalyst in lowered position.
• ‒ Mark position of propshaft with flexible coupling to bevel box flange.
• ‒ → Disconnect propshaft flexible coupling from bevel box flange (arrows).
• ‒ Push propshaft back onto stop.

Note:

→ When removing and installing the gearbox do not damage the sealing ring in the propshaft flange.

• ‒ Disconnect drive shaft from gearbox.
• ‒ Tie right drive shaft up as high as possible, when doing this do not damage surface protection.

• ‒ → Separate left ball joint/wishbone connection. (Mark installation position first).

• ‒ Assemble gearbox jack V.A.G 1383A with gearbox support 3282, adjustment plate 3282/18 for "02C" gearbox and support elements as follows:

• ‒ Place adjustment plate 3282/18 on gearbox support 3282. (Adjustment plate only fits in one position).
• ‒ Align arms of gearbox support according to holes in adjustment plate.
• ‒ → Bolt on support elements -A-, as illustrated on adjustment plate.

• ‒ → To enable the hook of gearbox support 3282 to engage remove bolt (arrow) in bevel box.
• ‒ Place jack V.A.G 1383 A with gearbox support 3282 under the gearbox and support the gearbox.
• ‒ Remove lower engine/gearbox securing bolts.
• ‒ Turn wheels fully onto left lock.

• ‒ → Lift engine/gearbox using support unit 10-222A spindles until there is sufficient clearance at sub-frame (arrow) to allow gearbox to be pressed off engine.
• ‒ Press gearbox off engine.

• ‒ → Set up press tool 3300 A .
• ‒ Press engine and gearbox forwards.
• ‒ Remove left drive shaft.

• ‒ Press gearbox further off engine.

• ‒ → Swing gearbox to rear to gain clearance between flywheel and bevel box housing.
• ‒ Thereby press gearbox further off engine.

• ‒ → Swing gearbox forwards (arrow), lower slightly and set at an angle using gearbox support 3282 so as to maintain clearance between body and top of gearbox.

• ‒ → Remove gearbox console.

• ‒ → Lower gearbox.

Notes:

• ◆ Do not damage P.A.S. pipe when lowering gearbox.
• ◆ Ensure that the gearbox does not contact sub-frame and press tool 3300 A.
• ◆ If the vehicle is to be moved with the drive shaft removed, then whilst the vehicle is still raised install an outer joint and tighten to 50 Nm. Otherwise the wheel bearing will be damaged.
• ◆ If the vehicle is to be moved with the propshaft detached then secure the propshaft to prevent damage.

Installing

Installation is carried out in the reverse sequence, when doing this note the following:

• ‒ → Before installing gearbox press clutch release lever towards gearbox housing and secure with assembly pin, assembly bolt or M8 x 35
  bolt. Remove after gearbox has been installed.
• ‒ When installing ensure dowel sleeves are seated correctly.

• ‒ Clean and lightly grease clutch release bearing, release bearing guide sleeve and input shaft splines with G 000 100 grease.

• ‒ Before swinging gearbox in to installation position:
• ‒ Insert left hand drive shaft.
• ‒ → Tighten left gearbox console to correct tightening torque => Tightening torques Page 34-51 .
• ‒ When swinging in gearbox do not damage seal in propshaft flange.

• ◆ → When installing the gearbox carrier the following assembly sequence is to be followed:
• ‒ Tighten all bolts hand-tight.
• ‒ Tighten bolts -A- to torque setting.
• ‒ Tighten bolts -B- and -C- to torque setting.
• ◆ Checking oil in gearbox with bevel box .
• ◆ Adjusting gear selector mechanism .

Tightening torques

→ Assembly mountings

→ Gearbox to engine

1)Also front console to gearbox

2)Also starter and front console to gearbox

• ‒ Items A + B - Dowel sleeves