Volkswagen Workshop Service and Repair Manuals

Removing gearbox, Golf 2004 ►, with 3.2 l V6 engine (all-wheel drive)

Special tools and workshop equipment required

t	Support bar -10 - 222 A- with hook -10 - 222 A /10-

t	Rack -10 - 222 A /1-

t	Adapter -10 - 222 A /18-

t	Hose clamps to 25 mm -3094-

t	Gearbox support -3282-

t	Adjustment plate -3282/42 A-

t	Ball joint puller -3287 A-

t	Engine and gearbox jack -V.A.G 1383 A-

t	Socket -T10035-

t	Tensioning strap -T10038-

t	Socket -T10061-

t	Assembly tool -T10071-

t	Locating pins -T10096-

t	Socket -T10107 A-

t	Insert tool, 18 mm -T10179-

t	Bracket -T10338-

t	Wing supports -T40045-

Removing: –  Before removing, print out diagnosis log for this vehicle. Before returning this gearbox in the usual manner, secure it to the gearbox so that it cannot be lost during transport. –  Observe general notes on removing and installing gearbox → Chapter. –  Raise vehicle. All 4 supports of lifting platform must be at same height.   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). –  Move selector lever to position »P« position. –  Disconnect battery → Rep. gr.27. –  Remove complete air filter housing → Rep. gr.24.

–  Remove bracket -arrows-.   Note Later, during the installation of the gearbox, there will still be an opportunity to check that the gearbox breather cap is »properly seated«.

–  Separate electrical connectors -1- and -3-. –  Unbolt electric wire -2- from starter solenoid. –  Unscrew earth line -4-. –  Loosen bayonet connection -5- by turning it and pull it off.   Caution Do not under any circumstances touch the contacts in the gearbox connector by hand. Static discharge could destroy the control unit and, consequently, the mechatronic unit.

If fitted, pull off breather line (to protect against water ingress -arrow-) from breather connection on gearbox.

–  Remove starter → Electrical system; Rep. gr.27. It is advisable to remove the »lower« bolt first. –  Remove selector lever cable from gearbox. Use pliers to remove the securing clip on the cable support bracket. Do not use a sharp-edged lever, as the rubber grommet on the cable could be damaged.

–  Push securing clip -A- upwards and remove in direction of arrow. –  Remove securing clip -B-. –  Press selector cable from selector shaft lever in -direction of arrow-, raise and lay to side.

Both securing clips must be later renewed when cable is adjusted. Remove cable with great care from cable support bracket on gearbox and bend. 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. –  Seal off gearbox oil cooler with clean plugs.

–  Unbolt cable retainer from front of gearbox cover -arrows-.

–  Disconnect -wiring harness- that comes out »from under« 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.

–  Remove footwell cover -1-. To do so, remove bolts -arrows-. –  Separate steering box from steering column. Refer to → Running gear, axles, steering; Rep. gr.48 to see what must be done. First bring steering wheel into centre position and engage steering lock. Notes on tightening the bolt can also be found in these instructions.

–  Remove all upper engine/gearbox connecting bolts. The following tools are appropriate for this: t  Socket -T10061- t  Socket -T10035- t  Insert tool, 18 mm -T10179- It is advisable to now do all the work which must be done »beneath« the car. This will avoid having the weight of the engine carried by the support bar and, consequently, by the body, for »a long time«. –  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. Removing subframe

–  Unscrew nuts -arrows- from lower suspension links on both sides.

–  Pull connector -3- off front left vehicle level sender -G78-. –  Remove both coupling rods from anti-roll bar. –  Unscrew nut from joint pin of track rod ball joint far enough that thread is flush with joint pin. When loosening, counterhold on joint pin if necessary. To protect thread, leave nut screwed a few turns onto joint pin.

–  Press track rod ball joint off wheel bearing housing with ball joint puller -3287 A-. Then unscrew nut.   Note Ensure that both lever arms of puller are parallel when the greatest force is exerted and adjust as necessary.

–  Unbolt bracket for exhaust system -1-. –  Remove pendulum support bolts -4-.

Before removing bolts -2- through -5- on both sides, have locating pins -T10096- at hand and support subframe with engine and gearbox support -V.A.G 1383 A-.

–  Once subframe has been supported, unscrew bolts -2- on both sides. As soon as bolt -2- has been removed, immediately insert a locating pin -T10096- in the „left and right“ sides. Do this for bolt -5- also. If the position of the subframe was not fixed, the wheels must now be aligned.

Important: remove bolt -1- and immediately install locating pin -2-. –  Carefully lower subframe. When doing this, observe wiring harness to engine compartment.

Remove subframe. –  Remove heat shield above right drive shaft. –  Unbolt both drive shafts from gearbox and carefully lay to side. –  Remove left drive shaft.

–  Secure right drive shaft to suspension strut with tensioning belt -T10038-.

–  Remove propshaft bolts -arrows- from gearbox.

The -seal- in the propshaft must not be damaged.

–  Therefore, jam assembly tool -T10071- in place using a cloth. This »protects« the ring.

–  Remove bracket -A- between cylinder block and bevel box. First remove bolt -1-. When installing, hand-tighten all bolts until the heads make contact. Then tighten bolts -2-.

–  If necessary, unscrew bracket with secondary pump (bolts -1- and -4-) and place to one side with secondary pump. –  Now remove all connecting bolts but one between engine and gearbox. It is advisable to leave an easily accessible bolt installed. –  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- and hooks -10 - 222 A /10-. Do not raise. –  Move »long« spindle on adapter -10 - 222 A /18- forwards.

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

Remove bracket -arrow-. Lower only slightly. As soon as the bracket can be removed, the space is sufficient to later guide the gearbox past the longitudinal member. Turn each spindle a maximum of 4 additional turns.

To remove dual clutch gearbox 02E, set up gearbox support -3282- with adjustment plate -3282/42 A- and push onto engine and gearbox support -V.A.G 1383 A-. –  Align arms of gearbox support with holes in adjustment plate -3282/42 A-. –  Screw support elements into adjustment plate -3282/42 A- as illustrated. The setup differs in one point: the -support plate with hole- is used as the front supporting element. –  Position engine and gearbox jack -V.A.G 1383 A- under vehicle. l  The arrow on the adjustment plate points in direction of travel. –  Align gearbox support -3282- parallel to gearbox. –  Screw pin -3282/29- into gearbox. –  Bolt -support plate with hole- to gearbox as shown in figure -arrow-. –  Insert last support element in gearbox as shown in figure. –  Support underside of gearbox by raising gearbox and engine support -V.A.G 1383 A-. 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. –  For purposes of analysis, attach diagnosis log for this gearbox securely to gearbox when it is ready for shipping. Transporting gearbox and securing to assembly stand → Chapter. Installing gearbox → Chapter.