Volkswagen Workshop Service and Repair Manuals

Removing gearbox –  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 near battery → Rep. gr.23 or → Rep. gr.24. –  Remove battery, battery cover 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 -arrow 1-. –  Release end-piece from gate selector cable → Fig.. –  Press catch -arrow 2- down to stop and remove relay lever together with cable end-piece. In the process, swing it in direction of operation. The relay lever was secured with a clip shortly after start of production → Fig.. –  Remove gearbox selector lever -A- by removing nut -arrow 3-.

–  Remove cable support bracket from gearbox -arrows-. –  Then raise and secure gear selector cable and gate selector cable. –  Remove retainer -B- from gearbox and pull it off pipe/hose line -A-.

–  Then remove gearbox support -arrow A-. –  Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes.   Caution Do not operate clutch pedal any more. –  Remove earth strap from top starter bolt.

–  Pull connector -arrow 1- off reversing light switch -F4-. –  Now remove connector -arrow 2- and wire -arrow 3- from starter. The starter does not need to be removed in order to remove the gearbox.

–  Remove upper engine/gearbox connecting bolts. –  Bolt bracket -T10346- to rear of the three mounting holes for battery tray. –  To do this, use a collar bolt M 6 x 80 or a securing bolt for battery tray. –  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- in front of bonnet support. –  Use: t  Adapter -10 - 222 A /3- t  Adapter -10 - 222 A /8- –  Position adapter -10 - 222 A /8-: l  On upper longitudinal carrier, directly before the elevation (-arrow 1-) next to bolt (-arrow 2-) –  Connect left support eye on engine to support bracket. –  Connect bracket -T10346- to support bracket. –  Take up weight of engine/gearbox assembly and support bracket on spindles. –  Raise vehicle. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50. –  Remove front left wheel housing liner → General body repairs, exterior; Rep. gr.66.

–  If front vehicle level sender -G78- is present, unbolt it from transverse link → Rep. gr.40.

–  Remove coolant circulation pump -V50--arrow 1-; do not open pipes → Rep. gr.19. –  Remove line for lambda probe from retainer for electrical lines on starter and from guides on charge air pipe -arrow 2- → Rep. gr.21. –  Remove charge air pipe -arrow 2- from engine so that it is not damaged on lowering gearbox → Rep. gr.21.

–  Remove left charge air hose -1- → Rep. gr.21.

–  Remove nut -arrow- and remove retainer for electrical lines. –  Remove securing bolts for starter.

–  Gearboxes for vehicles with start-stop system: pull connector -arrow- from gearbox neutral position sender -G701-.

–  Remove front part of exhaust system from engine → Rep. gr.26. –  Separate exhaust system -arrows 1- and remove exhaust pipe bracket from subframe -arrows 2- → Rep. gr.26.

–  Remove pendulum support.

–  Pull connector -1- off oil level and oil temperature sender -G266-.

–  Remove left drive shaft from gearbox, raise it as high as possible and secure it. → Running gear, axles, steering; Rep. gr.40 –  Remove drive shaft heat shield, if present -arrows- → Running gear, axles, steering; Rep. gr.40. –  Remove right drive shaft from gearbox, raise it as high as possible and secure it. → Running gear, axles, steering; Rep. gr.40

–  Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting. –  Lower gearbox by adjusting spindle attached to engine.

l  Securing bolts -arrows- for gearbox bracket -A- must be accessible. –  Remove gearbox bracket -A--arrows-.

–  If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it.

–  Unbolt right securing bolt for heat shield -1- from subframe. –  Secure retainer -T10346- with bolt -2-. -2- = Flange bolt M6 x 20 –  Secure engine support -3300 A- to bracket -T10346-. –  Place a cloth between engine support -3300 A- and oil pan. –  Carefully press engine and gearbox forwards.   Note t  Observe connecting lines, hoses and radiator when moving engine/gearbox assembly. t  Please make sure that adapters -10 - 222 A /8- are located entirely on longitudinal members, correcting as necessary using spindles of support bracket. To remove gearbox „02S“, set up gearbox support -3282- with adjustment plate -3282/39-. –  Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383A-. –  Align arms of gearbox support according to holes in adjustment plate.

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

–  Align adjustment plate parallel to gearbox and lock safety support on gearbox. –  Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

–  Remove engine/gearbox connecting bolts -arrows- in vicinity of sump.

–  Remove engine/gearbox connecting bolt -A- in area of right flange shaft.

–  Press gearbox off dowel sleeves and carefully swing towards subframe. –  Tilt gearbox further using spindles of gearbox support -3282-. l  Swing gearbox down near 6th gear.

–  Then guide right flange shaft past notch -arrow 1- in intermediate plate and past flywheel -arrow 2- (shown here with a different gearbox).

–  Guide left flange shaft -B- past subframe bracket -arrow- as shown. –  When lowering gearbox, change position of gearbox using spindles of gearbox support -3282-.   Note Be careful of all lines when lowering gearbox.