Volkswagen Workshop Service and Repair Manuals

Removing and installing gearbox Removing –  For vehicles with coded radio unit, note or obtain code. –  Disconnect battery earth strap. –  Remove battery from vehicles with 6-cylinder engine. –  Disconnect speedometer connector at gearbox. –  Pull connector off vehicle speed sender -G68-.

–  Remove electrical connections -arrows- on gearbox. –  Remove wiring harness from retainer and lay to side.

–  Pull connector off multifunction switch. –  Remove multifunction switch from vehicles with 6-cylinder engine. –  Move selector lever to position “P” and unbolt selector lever cable from selector shaft lever. –  Unclip securing clip at support bracket for selector lever cable and remove selector lever cable.

–  Clamp off ATF cooler hoses with hose clamps to 25 mm -3094- and detach from ATF cooler.

–  Insert support bracket -10 - 222 A- with rack -10 - 222 A /1- (6-cylinder engines adapters -10 - 222 A /3-) and support engine and gearbox in this position.

–  In vehicles with 6-cylinder engines, remove vacuum line -a- and connector -b- before hooking support bracket into eye -arrow-. –  Remove starter. –  Remove bracket for power steering pressure hose. –  For vehicles with 6-cylinder engine, pull connector off radiator fan motor.

–  Unbolt front bracket from engine carrier. –  Remove bracket. –  Remove expansion reservoir for coolant system and lay to side. –  Remove complete bracket for left assembly mounting. –  Remove upper engine/gearbox connecting bolts. –  Remove guard plate for ATF pan. –  Remove right cover for belt drive from vehicles with 6-cylinder engine. –  Unbolt torque converter cover plate and nuts from torque converter. –  Remove damper weight from 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 swivel joint bolts on left suspension link and remove bolts.

–  For vehicles with Plus running gear, remove bolts -A- and loosen bolt -B-. –  Lay left drive shaft to side, swinging swivel joint outwards. For drive shafts with triple roller joint, remove drive shaft. → Running gear; Rep. Gr.40.

–  Set up gearbox support -3282-. To remove automatic gearbox 096, set up gearbox support -3282- with adjustment plate -3282/2-. The symbols on the adjusting plate -3282/2- indicate the supports required.

–  Position engine and gearbox jack -V.A.G 1383 A- with gearbox support -3282- under gearbox and support gearbox.

–  Set pin of safety support against oil pan and secure to gearbox housing -arrow-. –  Remove lower engine/gearbox connecting bolts.

–  Tilt engine and gearbox forwards with engine support -3300 A-. –  Press gearbox off engine while simultaneously pressing torque converter out of drive plate. –  Press torque converter against ATF pump. –  Lower engine using spindle of support bracket. –  Lower gearbox slightly. –  When doing this, guide power steering pressure line past gearbox. –  Tilt gearbox using spindle of gearbox jack and, whilst lowering, guide cover on wheel housing side closely past wheel housing. –  Swivel gearbox and carefully lower. Ensure that right drive flange does not strike against engine support -3300 A-, nor multifunction switch against subframe. –  Secure torque converter to prevent it from falling out. Installing Install in reverse order of removal. When installing the torque converter, ensure that both drive pins engage in the recesses of the inner gear of the ATF pump. –  Before installing, ensure that dowel sleeves are correctly located. –  When installing gearbox, observe torque converter contact impression on drive plate. –  Replace securing clip on support bracket for selector lever cable. –  Check selector lever cable adjustment and adjust if necessary → Chapter.

Torque settings
Drive shaft to drive flange	45 Nm
Torque converter to drive plate	60 Nm
Gearbox to engine, M12 bolt	80 Nm
Gearbox to engine, M10 bolt	60 Nm
Front bracket to assembly mounting	60 Nm
Bracket to left assembly mounting	60 Nm
Left bracket to gearbox	25 Nm
Cover plate to gearbox	15 Nm
Swivel joint to suspension link	35 Nm
Starter to gearbox	60 Nm

Transporting automatic gearbox Use gearbox lifting tackle -3336- to transport automatic gearbox as well as to set up gearbox support -3282-.

–  Secure gearbox lifting tackle -3336- to gearbox housing flange. –  Position locking pins so that 8 holes are visible in chain direction.