Volkswagen Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ 10-222 A Support
• ◆ 10-222 A/1 Support
• ◆ 10-222 A/3 Adapter
• ◆ 3282 Gearbox support
• ◆ 3282/8 Adjustment plate
• ◆ 3336 Gearbox lifting beam

Special tools and workshop equipment required

• ◆ V.A.G 1331 Torque wrench
• ◆ V.A.G 1332 Torque wrench
• ◆ V.A.G 1383 A Gearbox jack

Removing

• ‒ Remove cover from engine.
• ‒ First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.

• ‒ With the ignition switched off disconnect the battery earth strap.
• ‒ Install battery.
• ‒ Remove battery carrier.
• ‒ → Remove cable support bracket from gearbox (arrows), if necessary unclip hose -A- at cable support bracket first.

• ‒ → Pull off gate selector cable -A- with relay lever, remove circlip -arrow 1- to do this.
• ‒ Remove gear selector cable -B- with gearbox selector lever, remove nut -arrow 2- to do this.
• ‒ Pull off gearbox selector lever, if necessary use puller Kukko 20-10.

• ‒ Tie selector cable with gearbox selector lever and gate selector cable with relay lever up.

• ‒ → Remove slave cylinder -arrows-, place to side and secure with wire, do not disconnect pipes.

Note:

Do not depress clutch pedal.

• ‒ Remove earth strap at engine/gearbox upper securing bolt.

• ‒ → Remove connector (arrow 1) from starter.
• ‒ Pull off reverse light connector (arrow 2).
• ‒ Remove cable retainer (arrow 3) on starter.
• ‒ Then remove upper securing bolt on starter.

• ‒ → Pull connector off speedometer sender (arrow).

• ‒ Remove engine/gearbox upper securing bolts.
• ‒ If there are hoses and cable connections in area of engine mounting eye for support 10-222A, remove these now.
• ‒ Remove left and right guides from wing.

=> General body repairs, exterior; Repair group 55; Bonnet

• ‒ → Fit support bar 10-222A together with legs 10-222 A/1 and adapters 10-222 A/3 .
• ‒ Take weight of engine/gearbox assembly on the spindles.
• ‒ Remove insulation tray below engine/gearbox, if fitted.
• ‒ Remove starter.

=> Repair group 27; Removing and installing starter.

• ‒ Remove right hand inner constant velocity joint protective cover from engine if fitted.

• ‒ Turn wheels fully onto left lock.

• ‒ Disconnect drive shafts from flanged shafts and tie up as high as possible, when doing this do not damage surface protection.
• ‒ → Remove P.A.S pipe -1- from gearbox console -arrow-.

• ‒ → Remove flywheel small cover plate -A- behind the right-hand flanged shaft (arrows), if fitted.
• ‒ Separate exhaust system after front exhaust pipe at double clamp.

• ‒ → Remove pendulum support (arrows A and B).

• ‒ → Remove hexagon bolts -arrows- of left-hand assembly mounting from gearbox.
• ‒ Incline the engine/gearbox assembly by lowering it via the left spindle of support bar 10-222A .

Note:

Ensure the sump does not lie against the assembly mounting when lowering the engine/gearbox assembly.

• ● The gearbox console -A- securing bolts (arrows) must be accessible.

• ‒ → Remove gearbox console -A- (arrows).
• ‒ Assemble gearbox jack with gearbox support 3282, adjustment plate 3282/8 for "02A" gearbox and support elements as follows:
• ‒ Place adjustment plate 3282/8 on gearbox support 3282. (Adjustment plate only fits in one position).
• ‒ Align arms of gearbox support according to holes in adjustment plate.

• ‒ → Bolt on support elements -A-, as illustrated, on adjustment plate.

• ‒ → Place gearbox jack under vehicle, arrow symbol -B- (=> Illustration V34-2670) on adjustment plate points to front of vehicle.
• ‒ Align adjustment plate parallel to gearbox and lock safety supports on gearbox.
• ‒ Remove lower engine/gearbox securing bolts.

• ‒ → Press gearbox off dowels and carefully swing towards sub-frame.

• ‒ → When lowering the gearbox, change position of gearbox using the gearbox support 3282 spindles -arrows- so that the rear gearbox (differential) is upwards.
• ‒ Both spindles -arrows- must be turned onto the stop as illustrated in the diagram.

• ‒ Press engine forwards carefully with the help of a second mechanic.

• ‒ → Then lower gearbox carefully, when doing this guide right-hand flange shaft -A- in area of flywheel as illustrated and guide left-hand flange shaft -B- in area of subframe.

Note:

Do not damage P.A.S pipe when lowering gearbox.

Transporting the gearbox

• ‒ → Bolt gearbox lifting device 3336 to clutch housing.

• ‒ → Set support arm on sliding piece with locking pin (arrow).

No. of holes visible = 5

• ‒ Lift gearbox with workshop crane and gearbox lifting device 3336.
• ‒ Place gearbox, for example onto transport container.

Installing

Notes:

• ◆ → Before installing gearbox press clutch release lever towards gearbox housing and secure with assembly pin, assembly bolt or M 8 x 35 bolt. Remove after gearbox has been installed. The hole will then be sealed by the 3rd cable support bracket securing bolt or plugged.

• ◆ → When replacing gearbox, the senders for speedometer (Fig.), gear selector and relay lever must be transferred to new assembly.

• ‒ Clean input shaft splines and lightly grease with G000 100 grease.

The clutch plate must be able to slide lightly to and fro on the input shaft.

• ‒ Check whether dowel sleeves for aligning engine/gearbox are fitted in cylinder block, install if necessary.
• ‒ Ensure that the intermediate plate is correctly positioned on engine.

• ‒ Assemble gearbox jack with gearbox support 3282, adjustment plate 3282/8 for "02A" gearbox and support elements as follows:
• ‒ Place adjustment plate 3282/8 on gearbox support 3282. (Adjustment plate only fits in one position).
• ‒ Align arms of gearbox support according to holes in adjustment plate.
• ‒ → Bolt on support elements -A-, as illustrated, on adjustment plate.

• ‒ → Place gearbox on gearbox jack.
• ‒ When lowering the gearbox change position of gearbox using the gearbox support 3282 spindles.
• ‒ Both spindles -arrows- must be turned onto the stop as illustrated in the diagram.

• ‒ Align adjustment plate and gearbox parallel with one another and lock safety supports on gearbox.
• ‒ → Place gearbox jack under vehicle, arrow symbol -B- (=> Illustration V34-2670) on adjustment plate points to front of vehicle.
• ‒ Insert gearbox.

Note:

Do not damage P.A.S pipe.

• ‒ Install lower engine/gearbox securing bolts.

• ‒ → Fit gearbox console -A- with new bolts (arrows).

• ‒ Align engine/gearbox in installation position.
• ‒ → Install new hexagon bolts -arrows- for left hand assembly mounting in gearbox mounting.

• ‒ Install upper engine/gearbox securing bolts.

• ‒ → Install pendulum support -arrows A and B-.
• ‒ Use new bolts for securing.
• ‒ Reconnect exhaust system.

=> Repair group 26; Removing and installing parts of the exhaust system.

• ‒ → Install P.A.S pipe -1- to gearbox console -arrow-.
• ‒ Install starter.

=> Repair group 27; Removing and installing starter.

• ‒ → If it was removed install small cover plate -A- behind right-hand drive flange (arrows).
• ‒ Fit drive shafts to gearbox.

=> Running gear, axles, steering; Repair group 40; Servicing drive shafts, Removing and installing drive shafts

• ‒ Install right-hand drive shaft protective cover if necessary.

• ‒ → Attach connector to speedometer sender (arrow).

• ‒ → Install cable retainer -A- on starter (arrow 3).
• ‒ Attach connectors for starter (arrow 1) and reversing light (arrow 2).

• ‒ → Install slave cylinder -arrows-.

• ‒ → Install cable support bracket on gearbox -arrows-, if necessary push hose -A- onto cable support bracket.

• ‒ → Fit gear selector cable -B- with gearbox selector lever (arrow 2).
• ‒ Fit gate selector cable -A- with relay lever and secure with a circlip (arrow 1).
• ‒ Install guide to wing.

=> General body repairs, exterior; Repair group 55; Bonnet

• ‒ Install battery carrier.
• ‒ Install battery.
• ‒ Reconnect earth strap to battery.

Note:

Note radio coding for vehicles with coded radio.

• ‒ Check gearbox oil .
• ‒ Specifications .
• ‒ Bleed clutch system .
• ‒ Adjusting gear selector mechanism => Page 34-18 .
• ‒ Install engine cover.
• ‒ Install insulation tray below engine/gearbox, if fitted.

Tightening torques

→ Gearbox to engine

     1)     Stud with drive

     2)     Also starter to gearbox

     3)     Small cover plate for flywheel

Items A + B - Dowel sleeves

→ Gearbox console -A- to gearbox

• ‒ Renew bolts

→ Gearbox to body

• ‒ Renew bolts

→ Rear gearbox mounting

• ‒ Renew bolts

Note:

Install engine/gearbox mountings stress-free.

=> Repair group 10; Removing and installing engine.