Volkswagen Workshop Service and Repair Manuals

Removing gearbox –  First check whether a coded radio is fitted. If so, obtain anti-theft code. –  With ignition switched off, disconnect battery earth strap → Electrical system; Rep. gr.27. –  If the lifting eyes of the engine for support bracket -10 - 222 A- are covered by a component, for example the air filter, it must be removed now. → Rep. gr.23 or → Rep. gr.24. –  Remove complete air filter housing if it is over the gearbox → Rep. gr.23 or → Rep. gr.24 –  Remove battery and battery tray → Electrical system; Rep. gr.27. –  Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

–  Pull gear selector cable off pin. Metal relay lever –  Remove securing clip -arrow 2- for gate selector cable from relay lever -B-. –  Pull gate selector cable from pin. –  Pull securing clip -arrow 3- off relay lever -B- and remove relay lever. Plastic relay lever –  Remove relay lever together with cable end-piece → Chapter. Continuation for all –  Remove gearbox selector lever -A- by removing nut -arrow 4-.

–  Remove cable support bracket from gearbox -arrows-. –  Then raise and secure gear selector cable and gate selector cable.

–  Pull line between master and slave cylinders -A- out of support -B-, if present, on gearbox. –  Remove slave cylinder -arrows-, lay to side and secure with wire. Do not disconnect pipes.   Note Do not depress clutch pedal. –  Remove earth strap at engine/gearbox upper connecting bolt or at subframe. –  Remove upper engine/gearbox connecting bolts. –  Then remove upper securing bolt on starter. –  If there are hose and cable connections in area of engine support eye for support bracket -10 - 222 A-, remove these now. Vehicles with petrol engine

–  Set up support bracket -10 - 222 A- together with adapters -10 - 222 A /8- in front of support for bonnet. Vehicles with diesel engine

–  Set up support bracket -10 - 222 A- together with adapters -10 - 222 A /8-, adapter -10 - 222 A /3- and adapter -10 - 222 A /16- before support for bonnet. –  Attach hook -10 - 222 A /10- at front right of engine.

–  Now attach hook -10 - 222 A /2- at rear left of engine -arrow-. –  Then connect hook -10 - 222 A /2- using adapter -10 - 222 A /16-. All vehicles –  Take up weight of engine/gearbox assembly on spindles. –  Raise vehicle. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50. –  Remove lower part of front left wheel housing liner → General body repairs, exterior; Rep. gr.66.

–  Pull off connector -1- for reversing light switch -F4-. –  If a nut -2- is installed, remove it now. –  Remove starter (bolt -3-) → Electrical system; Rep. gr.27.

–  Remove drive shaft heat shield, if present -arrows- → Running gear, axles, steering; Rep. gr.40. –  Separate exhaust system at double clamp and unbolt exhaust pipe bracket from subframe → Rep. gr.26. –  Remove drive shafts from flange shafts, raise as high as possible and secure. Do not damage the surface protection → Running gear, axles, steering; Rep. gr.40.

–  Remove engine/gearbox connecting bolt -A- in area of right flange shaft.   Note On some engines, the engine/gearbox connecting bolt is below the right flange shaft.

–  Check to see if a cover plate -A- is installed above the right flange shaft. –  Remove cover plate -A--arrows-.

–  Remove pendulum support → Running gear, axles, steering; Rep. gr.40.

–  Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting. –  Tilt engine/gearbox assembly by lowering the left spindle of support bracket -10 - 222 A-.   Note

t  In vehicles with a diesel engine, lower threaded spindle from adapter -10 - 222 A /16- using winged nut, but not more than until top of spindle is flush with top of nut -arrow-. t  All vehicles, when lowering the gearbox assembly, observer coolant hose between engine and heat exchanger, being careful not to stretch it. t  Be careful of all lines when lowering gearbox.

–  Unbolt gearbox support from gearbox -arrows-. To remove gearbox „0AF“, set up gearbox support -3282- with adjustment plate -3282/31-. –  Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383A-. –  Align arms of gearbox support according to holes in adjustment plate.

–  Attach support elements-A- to adjustment plate as illustrated. –  Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.

–  Align adjustment plate parallel to gearbox. –  Remove engine/gearbox connecting bolt -arrow- in figure above.

–  Remove engine/gearbox connecting bolts -arrows- in vicinity of sump (bolts remain on engine when exhaust system is in front of bolts).

–  For vehicles with a sheet metal sump, remove cover plate near sump -arrows-. –  Press gearbox off dowel sleeves. –  Observe intermediate plate on engine. –  Have a second mechanic press engine forwards.

–  Turn gearbox downwards, in area of differential, and turn rear of gearbox slightly towards front end -arrow 1-. –  If engine/gearbox connecting bolts -arrow 2- cannot be removed, ensure that they are backed out until they contact exhaust system.

–  Then carefully guide gearbox with right flange shaft past flywheel and intermediate plate -arrow 2- as shown. –  Lower gearbox, being careful of subframe -arrow 1-. –  When lowering gearbox, change position of gearbox using spindles of gearbox support -3282-.   Note Be careful of all lines when lowering gearbox.