Volkswagen Workshop Service and Repair Manuals

Removing gearbox, Golf 2004 ► with 1.4 l - 103 kW and 125 kW petrol engine Brief description The gearbox is removed downwards separately. »From above« Remove battery, air filter and starter. The coolant hoses must be clamped off. Left subframe mounting is removed and engine and gearbox supported. »From below«:

Remove -subframe- together with -pendulum support-, -steering box- and -both suspension links-.

For information on how to remove the -subframe-, refer to → Rep. gr.40. If the job is done correctly, the subframe can be removed and reinstalled without subsequently causing increased tyre wear, which may lead to customer complaints. It is recommended to read this information »before« removing gearbox. Then the position of the -subframe- can be properly fixed and the subframe removed. In any case, locating pins -T10096- are necessary.

If the position of the -subframe- is not fixed with the pins, the wheels must later be aligned. In this case, wheel alignment would be an unnecessary and expensive additional job! Save yourself this work and your customer the expense!

Special tools and workshop equipment required

t	Support bracket -10-222A-

t	Adapter -10-222A/3-

t	Hook- 10-222A/13-

t	Gearbox support -3282-

t	Adjustment plate -3282/42 A-

t	Insert tool 18 mm -T10179-

Special tools and workshop equipment required t  Tools without illustration: t  Pin -3282/29- t  Socket -T10061- t  Socket -T10035- t  Bit -T10099/1- t  Support -3282/59- t  If no hose clamps to 40 mm -3093- are available, use hose clamps to 25 mm -3094-. t  Engine and gearbox jack -V.A.G 1383 A- Removing: –  Raise vehicle. All 4 supports of lifting platform must be at same height. –  Move selector lever to position »P« position. –  Remove complete air filter housing → Rep. gr.24.

–  Remove battery and -battery box- → Rep. gr.27. –  Remove engine cover.

–  Remove starter → Electrical system; Rep. gr.27.

–  Remove selector lever cable from gearbox. Use pliers to remove the washer on the cable support bracket. Do not use a sharp-edged lever, as the rubber grommet on the cable could be damaged.

Both securing clips must be later renewed when cable is adjusted. Remove cable with great care from cable support bracket on gearbox. Do not bend it. Cable may also be pushed slightly backwards out of cable support bracket and removed later when gearbox is lowered. But then observe cable when lowering gearbox. During later installation, do not clip »small« securing clips on until cable has been checked and adjusted → Chapter.

–  Clamp off coolant hoses using hose clamps to 40 mm -3093- or hose clamps to 25 mm -3094- and remove. –  Unbolt wiring retainer from front of »black« gearbox cover (2 nuts M6). –  Release mechatronic unit connector by turning and pull off connector. –  Now remove all upper connecting bolts between gearbox and engine. Insert 18 mm -T10179- is especially good for this purpose. One bolt is located in hole for starter at the height of the solenoid. Socket -T10061-, 18 mm insert -T10179- or bit -T10099/1- can be used instead of an 18 mm socket.

–  Disconnect -wiring harness- coming »from below« from subframe.

–  Disconnect wire -1- from electronics box.

–  Disconnect earth cable -2-. –  Separate connector -3-. This wiring harness will later be removed together with the subframe. This will save time-consuming work on the steering and heat shield. –  If there are hose or wiring connections near the engine lifting eyes, remove them now.

–  Now separate steering from steering column. Refer to → Running gear, axles, steering; Rep. gr.48 to see what must be done. In any case, first return the steering wheel to the straight-ahead position. Engage steering wheel lock. Notes on tightening the bolt can also be found in these instructions. –  Separate steering box from steering column. –  Remove filler pieces from upper edges of both wings.

–  Support engine and gearbox with support bracket -10 - 222 A-, hooks -10 - 222 A /10- and adapter -10 - 222 A /13-. Do not raise.

–  Remove all bolts -1- and -2- for bracket -A-. –  Then lower engine and gearbox slightly using spindles of support bracket -10 - 222 A- so that bracket can be removed.

At most, 4 turns are sufficient to remove bracket -arrow-. –  Remove noise insulation and lower part of front left wheel housing liner → General body repairs, exterior; Rep. gr.66.

Next remove -subframe- together with -pendulum support- and -both suspension links- and -steering-. For information on how to remove the -subframe-, refer to → Rep. gr.40. If the job is done correctly, the subframe can be removed and reinstalled without subsequently causing increased tyre wear, which may lead to customer complaints. It is recommended to read this information »before« removing gearbox. Then the position of the -subframe- can be properly fixed and the subframe removed. If the position of the subframe was not fixed, the wheels must now be aligned. → Running gear, axles, steering; Rep. gr.40. When removing subframe, please remember:

–  After removing a bolt -1-, immediately screw in a locating pin -T10096--2-.

–  If fitted, remove the heat shield over the right-hand drive shaft. Tightening torque → Rep. gr.40 –  Unbolt drive shafts from gearbox and carefully lay to side. The surface protection of the shafts must not be damaged. Plastic cable ties or a pair of securing straps -T10038- are therefore very good for this. The air pipe and the electric coolant pump in front of the gearbox are still »in the way«. –  Remove brackets for air pipe and coolant pump. This is sufficient and creates space to support the gearbox. The coolant circuit and charge air pipe do not need to opened or separated, respectively. –  Set up gearbox support -3282- with adjustment plate -3282/42 A-.

–  Move engine and gearbox jack -V.A.G 1383 A- under gearbox and support gearbox. Do not raise. The gearbox is separated from the engine in this position. –  Remove remaining engine/gearbox connecting bolts.

A lower connecting bolt can be loosened but need not be removed. If this bolt needs to be renewed, the exhaust system must be separated. –  Press gearbox off engine, »observing selector lever cable« and lower gearbox. Transporting gearbox and securing to assembly stand → Chapter. Installing gearbox → Chapter.