Volkswagen Workshop Service and Repair Manuals

Removing gearbox –  First check whether a coded radio is fitted. If so, obtain anti-theft code. –  Remove cover from engine. –  With ignition switched off, disconnect battery earth strap. –  Remove battery. –  Remove battery carrier.

–  Remove intake hose -1-, connector -2- and hose -3- from air mass meter. –  Remove complete air filter housing by unscrewing bolts -4- and -5-. –  Remove intake hose -1-.

–  Unbolt bracket -arrow- from gearbox. –  Place selector lever in “P” and pry selector lever cable -1- off lever of selector shaft -4- with a screwdriver. –  Do not loosen bolt -2-. –  Unclip securing clip -3- at support bracket for selector lever cable and remove selector lever cable.

–  Do not kink selector lever cable.

–  Pull connector -1- off wire for multifunction switch. –  Turn locking lever -2- and unplug connector for gearbox wiring harness. –  Remove electrical connections on starter. –  Remove starter -3-. → Electrical system; Repair group 27; Starter motor; Removing and installing starter motor

–  Clamp off and remove ATF cooler hoses. –  Seal ATF cooler with clean plugs. –  Remove upper engine/gearbox connecting bolts with socket -T10099/1-. –  Loosen fuel line at cylinder head cover. –  If there are hose and cable connections in area of engine mounting eye for support 10-222A, remove these now.

–  Assemble support bracket 10-222A in conjunction with adapters 10-222A/3 and 10-222 A/8. –  Take up weight of engine/gearbox assembly on spindles. –  Remove front left wheel bolts. –  Raise vehicle. –  Remove left wheel.

–  Remove noise insulation tray -arrows-.

–  Remove left noise insulation -arrows-. –  Separate pressure pipe between charge air cooler and turbocharger from longitudinal member. –  Remove right noise insulation. –  Remove front exhaust system with catalytic converter. → Engine - mechanics; Repair group 26; Removing and installing parts of exhaust system.

–  Remove earth strap -1- from bracket on gearbox. –  Remove line -2- from front of gearbox -arrows-. –  Remove bracket -3-. –  Then remove power steering line from back of gearbox (near pendulum support) and tie off to one side. –  Remove retainer from valve body cover. –  Disconnect drive shafts at gearbox flanges. –  Raise right drive shaft and secure.

–  Remove lower rear engine/gearbox connecting bolt -A-. –  Unclip cap for cover for torque converter nuts. –  Remove nuts -arrow- from torque converter (Qty. 3) using socket V 175. –  Turn crankshaft through 120° for each bolt. –  Loosen retainer -B- for line for oil temperature and level sender and turn to side. –  Turn steering to left lock. –  Mark installation position of swivel joint bolts on left suspension link and remove bolts.

–  Remove bolts -arrows-.

–  Separate left coupling rod -1- from suspension link and turn coupling rod upwards. –  Swing wheel bearing housing outwards. –  Raise left drive shaft -2- between subframe and gearbox and secure to suspension strut with wire.

–  Remove lower engine/gearbox connecting bolts -2- and -3-. –  When doing this, remove bracket -1- for earth strap from gearbox. –  Do not yet remove connecting bolt -4-. –  Remove pendulum support.

–  Unbolt left assembly mounting from bracket. –  Carefully tilt engine and gearbox. Do this by turning down both spindles about 90 mm.

–  Turn right flange shaft -B- so that “flattened sections” are vertical. –  Bolt support -T10036- to subframe -A-. –  Fit engine support -3300 A- so that it almost touches subframe and bolt on -arrows-. –  Carefully press engine and gearbox forwards.   Note Do not overstretch lines in the process. Set up gearbox support 3282 with adjustment plate 3282/32. –  Align arms of gearbox support according to holes in adjustment plate.

–  Screw in support elements -A- as illustrated on adjustment plate. Arrow -B- points in direction of travel. –  Align adjustment plate parallel to gearbox.

–  Secure gearbox to gearbox support 3282 with bolt -A-. –  Remove engine/gearbox connecting bolt -arrow-.

–  Press gearbox off engine while simultaneously pressing torque converter out of drive plate. –  Press torque converter against ATF pump -arrow-. –  Carefully swivel gearbox towards subframe.

–  Carefully lower gearbox, guiding right flange shaft -A- past drive plate and left flange shaft -B- past subframe. –  When lowering, ensure “clearance” between gearbox and other components. Adjust gearbox 3282 as necessary. –  Secure torque converter to prevent it from falling out.

–  If the gearbox is to be renewed, the gearbox bracket -A- must be transferred to the new gearbox -arrow-.