Volkswagen Workshop Service and Repair Manuals

Removing

Note:

Different work sequences for vehicles with Diesel engine .

• ‒ Disconnect earth strap from battery

Note:

Note radio coding for vehicles with coded radio.

• ‒ Depress clutch pedal several times down onto stop.
• ‒ Tension clutch cable and detach from gearbox.

Up to 26.04.95

From 27.04.95

• ‒ → Pull connector off road speed sender (arrow).

• ‒ Unbolt earth wire.
• ‒ Remove engine/gearbox upper securing bolts.
• ‒ Remove insulation tray below engine/gearbox, if fitted.

• ‒ → Pull off reversing light connector (arrow 1).
• ‒ Unclip retainer for connector out of eye on gearbox (arrow 2)
• ‒ Disconnect drive shafts from flanged shafts, turn steering to full left lock.
• ‒ Tie-up left-hand drive shaft as high as possible.

• ‒ → Remove selector finger -A- by loosening bolt (arrow 1).
• ‒ Lever off cable circlip between selector lever and gearbox, at gearbox (arrow 2), if fitted.
• ‒ Lever off cable running between selector lever and gearbox, at gearbox (arrow 2).

Vehicles with cable selector control:

• ‒ Remove gear change cable and gate change cable from gearbox
• ‒ Remove support bracket

• ‒ Remove flywheel cover plate.
• ‒ → Remove pendulum support, to do this remove bolts -3- and nut -2- and take out bolt -1-.

• ‒ → Remove support for intake manifold, if fitted (arrow)
• ‒ Remove starter.

=> Repair group 27; Removing and installing starter.

For vehicles with an oval air cleaner:

• ‒ Remove cover from air cleaner.

• ‒ → Fit support bar 10-222A together with legs 10-222 A/1.
• ‒ Take weight of engine/gearbox assembly on the spindles.

• ‒ → Remove hexagon bolts (arrows) from left-hand gearbox mounting console.
• ‒ Carefully tilt engine and gearbox. To do this lower left-hand spindle slightly on support bar 10-222 A.

Vehicles with petrol engine and rod selector mechanism

• ‒ → Use adjusting plate 3282/6 to align gearbox support 3282.
• ‒ Place adjustment plate 3282/6 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 V34-2578) on adjustment plate points to front of vehicle.
• ‒ Align adjustment plate parallel to gearbox and lock safety supports on gearbox.

Vehicles with petrol engine and cable selector mechanism

• ‒ → Use adjusting plate 3282/20 to align gearbox support 3282.
• ‒ Place adjustment plate 3282/20 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 N 34-0190) on adjustment plate points to front of vehicle.

• ‒ → Secure gearbox to gearbox support 3282 with bolt -A-

Continuation for all vehicles

• ‒ Remove lower engine/gearbox securing bolts.
• ‒ Press gearbox off dowels and lower carefully.

Vehicles with Diesel engine, note different work sequence:

→ The starter is fitted in front of gearbox (arrow).

• ‒ If fitted remove the insulation tray below engine/gearbox before removing starter.
• ‒ Remove starter.

=> Repair group 27; Removing and installing starter.

• ‒ → Unscrew pin (arrow) for cable between gear change mechanism and gearbox.

The pin hole is required to secure gearbox to gearbox mounting 3282 .

• ‒ Use adjusting plate 3282/20 to align gearbox support 3882.
• ‒ Place adjustment plate 3282/20 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 N 34-0190) on adjustment plate points to front of vehicle.
• ‒ Align adjustment plate parallel to gearbox.

• ‒ → Secure gearbox to gearbox support 3282 with bolt -A-

Transporting the automatic gearbox

Special tool 3336 may be used to transport the gearbox and also when setting up gearbox mounting 3282.

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

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

No. of holes visible = 9

• ‒ Take gearbox out with workshop crane and gearbox lifting device 3336.

Installing

Note:

Modifications on vehicles with Diesel engine .

• ‒ 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 3282/6 for "084", "085" gearbox and support elements as follows:
• ‒ Place adjustment plate 3282/6 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.

• ‒ Align adjustment plate and gearbox parallel with one another and lock safety supports on gearbox.
• ‒ → Place gearbox jack under vehicle, arrow symbol -B- (=> Illustration V34-2578 on previous page) on adjustment plate points to front of vehicle.
• ‒ Insert gearbox.
• ‒ Install lower engine/gearbox securing bolts.

• ‒ Align engine/gearbox in installation position. To do this tighten the left-hand spindle on support bar 10-222 A.
• ‒ → Insert left-hand gearbox console hexagon bolts (arrows) and tighten to torque setting.
• ‒ Remove support bar 10-222A.

• ‒ Install upper engine/gearbox securing bolts.

• ‒ If necessary fit air cleaner cover.
• ‒ Install starter.

=> Repair group 27; Removing and installing starter.

• ‒ → Install support for intake manifold (arrow)

• ‒ → Install pendulum support, to do this insert bolt -1- and install nut -2- and bolts -3-.

• ‒ Install flywheel cover plate.
• ‒ Clean threaded hole in selector finger with M8 tap.
• ‒ → Always replace selector finger securing bolt (arrow 1). The bolt is to be pre-treated with locking fluid.
• ‒ Push selector finger onto inner selector finger so far as to allow the securing bolt (arrow 1) to fit into the forward recess on the selector lever (arrow 2).

• ‒ Renew bush in cable between selector mechanism and gearbox (arrow).
• ‒ → Press cable, running between selector mechanism and gearbox, on at gearbox (arrow).
• ‒ Fit circlip for cable running between selector lever and gearbox, at gearbox, if fitted.

Vehicles with cable selector control:

• ‒ Install gear change cable and gate change cable to gearbox
• ‒ Install support bracket

• ‒ Fit drive shafts to flange shafts.

• ‒ → Clip retainer for connectors into eye on gearbox (arrow 2).
• ‒ Reconnect reverse light connector (arrow 1).
• ‒ Install insulation tray below engine/gearbox, if fitted.
• ‒ Install upper engine/gearbox securing bolts.
• ‒ Bolt on earth wire.

• ‒ → Reconnect speedometer sender connector (arrow).

Notes:

• ◆ → The spring (arrow) if fitted between release lever and gearbox must be unconditionally removed, otherwise the function of the clutch cable adjustment mechanism cannot be guaranteed!
• ◆ The spring is only required for securing the release bearing during transport.

• ‒ Install clutch cable to gearbox.

Up to 26.04.95 =>from Page 30-10

From 27.04.95 =>from Page 30-17

• ‒ Reconnect earth strap to battery.

Note:

Note radio coding for vehicles with coded radio.

• ‒ Checking gearbox oil .
• ‒ Adjusting selector mechanism:

Rod selector mechanism .

Cable selector mechanism => Page 34-41

Tightening torques

Gearbox to engine

→ Engine block of cast iron (painted black)

Items A + B - Dowel sleeves

Gearbox to engine

→ Engine block of aluminium (metallic brilliant)

     1)     Flywheel shield securing bolts

Items A + B - Dowel sleeves

Assembly mountings

• ‒ 1) Tighten nut to tightening torque. Counterhold bolt so that the rubber bush is not stressed/turned

Modification from 12.96

From vehicle identification No.: 6N ZVW 133102

modified hexagon bolts -3- have been introduced.

• Hexagon bolts -3-, M8 x 22; strength class 9.1
• Tightening torque; 20 Nm and turn 90° further
• Renew hexagon bolts after each removal

The following modifications should be noted on vehicles with Diesel engine:

• ‒ → Use the new adjusting plate 3282/20 to align the gearbox support 3882.

• ‒ → Remove bolt -A- after gearbox is bolted to engine.

• ‒ → For rod selector mechanism, screw pin (arrow) for selector mechanism cable into threaded hole.

→ Install starter (arrow) before installing gearbox.

=> Repair group 27; Removing and installing starter.

The clutch housing flange and the securing bolts have been matched to the Diesel engine.

Tightening torques

→ Gearbox to engine

     1)     Flywheel shield securing bolts

     2)     Also starter to gearbox

Items A + B = Dowel sleeves