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. At a later point, the support bracket -10 - 222 A- will be connected to the lifting eyes of engine. –  If engine cover blocks access, remove engine cover. –  Remove air filter with engine cover if it is located close to the battery → Rep. gr.24. –  Remove battery, battery cover and battery tray → Electrical system; Rep. gr.27.

–  Remove securing clip -3- for gear selector cable from gearbox selector lever -1- and pull cable off pin -arrow-. Metal relay lever –  Remove securing clip -4- for gate selector cable from relay lever -2- and pull cable off pin -arrow-. Plastic relay lever

Releasing cable end-piece from gate selector cable l  To avoid damage to gate selector cable, separate cable end-piece from gate selector cable before removal. –  Pull locking mechanism forwards onto stop in direction of -arrow 1- and then lock by turning anti-clockwise in direction of -arrow 2-. –  Push relay lever forwards (-direction of arrow 3-). –  Remove relay lever made from plastic together with cable end-piece as work procedure continues. Continuation for all

–  Remove cable support bracket from gearbox -arrows-, lay to side and secure with wire.

–  If a plastic line is installed, clamp off supply hose to master cylinder using hose clamps up to 25 mm -3094-.

–  If a pipe/hose line is installed, clamp off hose of pipe/hose line -A- to slave cylinder using hose clamps up to 25 mm -3094-. –  Pull out clip -arrow- for pipe/hose line or plastic line to stop. –  Pull pipe/hose line or plastic line out from slave cylinder bleeder and seal.   Caution Do not operate clutch pedal any more.

–  Remove earth strap -1- from top starter bolt. –  Disconnect electrical connector -2- for reversing light switch -F4-. –  Remove connector and wire from starter.

–  Remove upper engine/gearbox connecting bolts -arrows-. –  Then remove upper securing bolt on starter. –  Remove foam pieces from upper edge of left and right wings → Body, front; Rep. gr.50. –  If there are hose and cable connections in area of engine support eye for support bracket -10 - 222 A-, remove these now.

–  Set up support bracket -10 - 222 A- together with adapters -10 - 222 A /13- and hook -10 - 222 A /10- in front of bonnet gas struts. –  Attach hook -10 - 222 A /10- in engine support eye. –  Take up weight of engine/gearbox assembly on spindles.   Note

t  Check whether an intermediate shaft -arrow- is installed between right drive shaft -A- and gearbox.

t  For vehicles with intermediate shaft, with vehicle standing on its wheels, loosen flange bolt -2- for right drive shaft -1- a maximum of 90°. Otherwise, wheel bearing will be damaged → Running gear, axles, steering; Rep. gr.40. –  Loosen wheel bolts on front left and front right. –  Raise vehicle. –  Remove front wheels. –  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.

–  If present, remove front vehicle lever sender -G78--arrows- → Running gear, axles, steering; Rep. gr.40. –  Remove bracket from starter. –  Remove starter → Electrical system; Rep. gr.27.

–  Separate connection -arrow 1- or -arrow 2- on charge air hose.

–  Remove exhaust system bracket from subframe -arrows-.

–  Separate exhaust system at double clamp -arrows-. –  Tie up front exhaust pipe.

–  If present, remove support -1- for exhaust system from gearbox -arrow- and front exhaust pipe.

–  Remove pendulum support from gearbox, bolt -2- and bolt -3-. –  Pull off connector from sender for oil level and oil temperature -G266-. –  Disconnect left drive shaft from gearbox flange shaft. –  Secure drive shafts with wire. When doing this, do not damage surface protection.

If an intermediate shaft -C- is present, remove right drive shaft -A-. Then remove intermediate shaft from mounting bracket -D--arrows- and pull this off from stub shaft of gearbox.

If there is no intermediate shaft, separate right drive shaft only from flange shaft -A- of gearbox.

–  To do this remove drive shaft cover from engine (bolts -1-) → Running gear, axles, steering; Rep. gr.40. –  Secure drive shaft with wire. Continuation for all –  Separate left and right coupling rods from anti-roll bar.

–  Unscrew nuts -arrows- for swivel joint on suspension links. –  Fix subframe in position prior to removal → Running gear, axles, steering; Rep. gr.40. –  Remove subframe with pendulum support, anti-roll bar, brackets and suspension links → Running gear, axles, steering; Rep. gr.40.

–  Remove hexagon bolts -arrows- on left engine/gearbox mounting -2- from bracket -1-.

–  Lower gearbox about 60 mm, -a- by adjusting spindles.   Note When moving engine and gearbox assembly, observe coolant hose between engine and heat exchanger, being careful not to stretch it.

–  Remove bracket -1- from gearbox -arrows-. Metal relay lever

–  Pull securing clip -arrow- off relay lever -1- and remove relay lever. Plastic relay lever –  Removing relay lever together with cable end-piece → Chapter. Continuation for all –  Remove selector lever from selector shaft.

–  Remove engine/gearbox connecting bolt -arrow-. –  Remove small cover plate -A- for flywheel.

–  Remove lower engine/gearbox connecting bolts -2-.   Note Loosen engine/gearbox connecting bolt -3- and leave it installed just hand-tight. To remove gearbox „02Q“, set up gearbox support -3282- with adjustment plate -3282/33-. –  Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383 A-. –  Align arms of gearbox support according to holes in adjustment plate.

–  Attach support elements-A- to adjustment plate as illustrated. –  Screw in pin -3282/29- instead of support element-C-. –  Position engine and gearbox jack -V.A.G 1383 A- under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel. –  Align adjustment plate parallel to gearbox.

–  Secure adapter -VW 771/40- in threaded hole of gearbox housing as shown in figure. –  Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support. –  Secure gearbox to gearbox support -3282- using bolt (M10x20) -A-. Pin -B- must lie flush with guide from gearbox support -3282- at bottom -arrow-. –  Remove last engine/gearbox connecting bolt -C-. –  Press gearbox away from engine, off dowel sleeves. –  Raise gearbox near differential via spindle of gearbox support -3282-. –  Rotate gearbox to left via spindle of gearbox support -3282-. –  Lower gearbox carefully.   Note t  When lowering gearbox, observe, if appropriate, steering box. t  Be careful of all lines when lowering gearbox.