Volkswagen Workshop Service and Repair Manuals

Removing gearbox, Golf 2004 ► with 147 kW - 2.0 l 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  If no hose clamps to 40 mm -3093- are available, use hose clamps to 25 mm -3094-. t  Pin -3282/29- t  Support -3282/59- 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.   Note After loosening centre bolt, do not lower vehicle to ground again.

–  Depress brake pedal to remove bolt for left drive shaft -arrow- (second mechanic required). –  Remove complete air filter housing → Rep. gr.24.

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

–  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. –  Remove filler pieces from upper edges of both wings. –  If there are hoses and cable connections in area of engine support eyes for support bracket -10-222A-, remove these now.

–  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.

Remove bracket -arrow-. –  Remove noise insulation and lower part of front left wheel housing liner → General body repairs, exterior; Rep. gr.66. –  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. If the subframe is removed now, the left drive shaft may be removed.

Now remove -subframe- → Rep. gr.40. 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.

–  A small cover plate is located above the right drive shaft flange on the intermediate plate for engine and gearbox. Remove cover plate -A-. –  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. –  Press gearbox off engine, »observing selector lever cable« and lower gearbox. Transporting gearbox and securing to assembly stand → Chapter. Installing gearbox → Chapter.