Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ Engine support bracket 10-222A with supports10-222A/1
• ◆ Adapter 10-222A/3 (6-cylinder engine)
• ◆ Hose clamps 3094
• ◆ Gearbox support 3282
• ◆ Alignment plate 3282/2
• ◆ 3300 A
• ◆ Engine/gearbox jack V.A.G 1383 A
• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ V.A.G 1332 Torque wrench (40...200 Nm)

Removing

• ‒ Obtain radio code on vehicles with coded radio.
• ‒ Disconnect battery earth strap.
• ‒ Remove battery on vehicles with 6-cylinder engines.
• ‒ Disconnect speedometer connector at gearbox.

• ‒ Disconnect speedometer sender -G68- connector.
• ‒ → Remove electrical connections (arrows) at gearbox.
• ‒ Remove wiring harness from retainer and place to the side.

• ‒ → Pull connector off multi-function switch.
• ‒ Remove multi-function switch on vehicles with 6-cylinder engine.
• ‒ Move selector lever to "P" and unscrew selector lever cable from lever/selector shaft.
• ‒ Remove selector lever cable anchorage circlip and remove selector lever cable.

Gearboxes with clipped selector lever cable:

• ‒ → Release selector lever cable first -1- then remove from support bracket -2-.

• ‒ → Clamp-off ATF cooler hoses with -3094- and detach at ATF cooler.

• ‒ → Fit support bar 10-222 A with legs 10-222 A/1 (6-cyl. engine adapter 10-222 A/3) and support engine/gearbox in this position.

• ‒ → Remove vacuum pipe -a- and connector -b- before inserting support bar into eye (arrow) on vehicles with 6-cylinder engines.
• ‒ Remove starter.
• ‒ Remove bracket for power assisted steering pressure hose.

• ‒ Pull connector off radiator fan motor on vehicles with 6-cylinder engine.

• ‒ → Unscrew front console from engine carrier.
• ‒ Remove console.
• ‒ Unscrew coolant expansion tank and lay to one side.
• ‒ Remove left engine mounting console complete.
• ‒ Remove upper engine/gearbox connecting bolts.
• ‒ On vehicles with 6-Cyl. engines mark connecting bolts .
• ‒ Remove ATF oil pan protective plate.
• ‒ Remove right-hand belt drive cover on vehicles with 6-cylinder engine.
• ‒ Remove torque converter cover plate and nuts from torque converter.
• ‒ Remove vibration damping weight on vehicles with 6-cylinder engine.
• ‒ Disconnect drive shafts at flanges.
• ‒ Raise right drive shaft and secure.
• ‒ Remove left wheel.

• ‒ Turn steering to right lock.
• ‒ Mark installation position of ball joint bolts on left-hand wishbone and remove bolts.
• ‒ → Vehicles with plus running gear, remove outer bolts and loosen inner bolts.
• ‒ Swing ball joint outwards and place left-hand drive shaft to one side. Remove drive shaft with triple roller joint.

=> Running gear; Repair group 40; Removing and installing drive shafts.

• ‒ → Set up gearbox support 3282.

The gearbox support 3282 is set up with the adjusting plate 3282/2 for removing the automatic gearbox 01M.

The symbols on the adjusting plate indicate the supports required.

• ‒ → Move jack V.A.G 1383 A with gearbox support 3282 under the gearbox and support gearbox.

• ‒ → Place safety support pin on sump and secure to gearbox housing (arrow).
• ‒ Remove lower engine/gearbox connecting bolts.

• ‒ → Tilt engine and gearbox forwards with supporting device 3300 A.
• ‒ Press gearbox off engine; when doing this, press torque converter out of drive plate.
• ‒ Press torque converter against ATF pump.
• ‒ Lower engine using support device spindle.
• ‒ Lower gearbox slightly.
• ‒ When doing this guide the power assisted steering pressure pipe past the gearbox.
• ‒ Tilt gearbox using gearbox jack spindle and whilst lowering ensure cover (wheel housing side) is guided closely past wheel housing.
• ‒ Swivel gearbox and carefully lower.

Ensure that the right joint flange does not contact the supporting device 3300 A and that the multi-function switch does not contact the subframe.

• ‒ Secure torque converter to prevent it falling out.

Installing

Installation is performed in the reverse order.

• ‒ Before installing the torque converter, observe sleeve bearing in turbine shaft .

When installing the torque converter, ensure that both drive pins engage in the ATF pump inner wheel recesses.

• ‒ Before installing, ensure that the dowel sleeves are correctly located.
• ‒ When installing gearbox, observe torque converter contact impression on drive plate.

Vehicles with 6-cyl. engine

If the gearbox has not been renewed:

• ‒ Do not interchange upper engine/gearbox connecting bolts and install in the same position.

→ Flange thickness -arrow-: 55 mm

Pos. A = Dowel sleeves for centralising

     1)     Hexagon bolt with threaded shank M8 x 10

     2)     Cover plate to gearbox

When installing a new gearbox note the following:

When installing new gearboxes, special care must be taken regarding the length of the engine/gearbox connecting bolts.

New gearboxes have a flange thickness reduced by 25 mm -arrow- and modified connecting bolts.

→ Flange thickness -arrow-: 30 mm

Pos. A = Dowel sleeves for centralising

1)The cylinder block will be damaged if the bolt is too long when tightening.

     2)     Hexagon bolt with threaded pin M 8 x 10

     3)     Cover plate to gearbox

     4)     When tightening the thread in the gearbox will be damaged if the bolt is too short.

• ‒ When installing a new gearbox with modified flange, modified bolts must be installed at Pos. 1, 4 and 6.

Continued for all vehicles

• ‒ Replace selector cable anchorage locking washer.
• ‒ Check selector lever cable adjustment, adjust if necessary => Page 37-3 .
• ‒ Check and top up ATF level .
• ‒ Perform self-diagnosis and initiate basic setting.

=> Self-diagnosis for automatic gearbox 01M - from 01.95; Repair group 01; Performing self-diagnosis

in booklet:

• ◆ Workshop Manual Golf 1992 ▸, Vento 1992 ▸ Self-diagnosis for automatic gearbox 01M - from 01.95

Tightening torques