Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ 10-222 A Support
• ◆ 10-222 A/1 Support
• ◆ V.A.G 1383 A Gearbox jack
• ◆ 3282 Gearbox support
• ◆ 3282/8 Adjustment plate
• ◆ 3282/48 Pin (3x)
• ◆ 3282/59 Support

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ 3300 A Engine support
• ◆ VW 457/1 Support rails (modifying => next page)
• ◆ 3336 Gearbox lifting beam

Additionally for vehicles with 5 and 6-Cyl. engines

• ◆ 10-222 A/3 Adapter
• ◆ 10-222 A/2 Special hook

Modifying support rail VW 457/1

• ‒ Support rails VW 457/1 are required to remove and install the gearbox.

→ To secure support rail VW 457/1 to the subframe a new hole is required.

Dimensions given are in mm.

• ‒ Drill a 8.5 mm ø hole (arrow) in support rail VW 457/1.

Removing

• ‒ 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.
• ‒ Remove cover from engine.
• ‒ → Remove intake hose -1- , connector -2- and hose -3- from air mass meter.
• ‒ Remove complete air cleaner housing, to do this, unscrew bolts -4- and -5-.

=> Repair group 24; Removing and installing air cleaner

Gearboxes up to 05.99

• ‒ → Pull connector off road speed sender (arrow 1).

• ‒ Pull off reverse light connector (arrow 2).

• ‒ → Remove balance weight -A- and gear selector cable -B- from gear selector lever.
• ‒ Take off gear selector cable with washer and square nut (self-locking).
• ‒ Pull gate selector cable off actuating arm/relay lever -C- to do this lift lug in direction of arrow.

• ‒ → Remove cable support bracket from gearbox (arrows), if necessary unclip hose at cable support bracket first.

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

Note:

Do not depress clutch pedal.

• ‒ → Remove cable retainer (arrow 1) on starter.
• ‒ Then remove upper securing bolt (arrow 2) on starter.
• ‒ Remove earth strap at engine/gearbox upper securing bolt.
• ‒ Remove engine/gearbox upper securing bolts.

Gearboxes from 05.99

• ‒ → Remove cable support bracket from gearbox (arrows), if necessary unclip hose at cable support bracket first.

• ‒ → Pull off gate selector cable -A- with relay lever, remove circlip (arrow) to do this.
• ‒ Remove gear selector cable -B- with gearbox selector lever, remove nut (arrow) to do this.
• ‒ Tie selector cable with gearbox selector lever and gate selector cable with relay lever up.

• ‒ → Pull connector off road speed sender (arrow 1).

• ‒ Pull off reverse light connector (arrow 2).

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

Note:

Do not depress clutch pedal.

• ‒ → Remove cable retainer (arrow 1) on starter.
• ‒ Remove wiring and cable from starter.
• ‒ Remove earth strap at engine/gearbox upper securing bolt.
• ‒ Then remove upper securing bolt (arrow 2) on starter.
• ‒ 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.

→ Continued for vehicles with 4-Cyl. engine

• ‒ Fit support bar 10-222A together with legs 10-222 A/1.

→ Continued for vehicles with 5 and 6-Cyl. engines

• ‒ Fit support bar 10-222A together with legs 10-222 A/1 and adapters 10-222 A/3 .

• ‒ → If the lifting eye is attached to the lower part of the engine then additional hook 10-222 A/2 is to be used.

Continuation for all vehicles

• ‒ Take weight of engine/gearbox assembly on the spindles.
• ‒ If fitted, remove centre and left part of insulation tray below engine/gearbox.
• ‒ Remove P.A.S pipe from starter and gearbox.
• ‒ Remove starter.

=> Electrical system; Repair group 27; Starter motor; Removing and installing starter motor

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

=> Running gear, axles, steering; Repair group 40; Servicing front suspension; Removing and installing swivel joint

• ‒ 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 flywheel small cover plate -A- behind the right-hand flanged shaft (arrows), if fitted.
• ‒ Remove lower flywheel cover plate, if part of original equipment.

• ‒ Separate exhaust system and if necessary remove from sub-frame.

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

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

• ‒ → Then remove gearbox support (arrow A) from gearbox.
• ‒ Remove hexagon bolts (arrows B) from left-hand hand assembly mounting.

• ‒ Incline the engine/gearbox assembly by lowering it via the left spindle of support bar 10-222A .

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

• ‒ → Remove gearbox console -A- (arrows).

• ‒ → Bolt support rail VW 457/1 to both pendulum support securing holes on subframe.
• ‒ Spacers totalling 6 mm must be inserted between subframe and support rail VW 457/1.

-A- Qty. 2 hexagon bolts M 8 x 25

• ‒ Fit support 3300 A and secure (arrows).

→ Vehicles with 5 valve engine

• ‒ Remove a lower engine/gearbox securing bolt so that the support 3300 A can be fitted.
• ‒ The support 3300 A must be fitted on the engine directly next to the gearbox.

Continuation for all vehicles

• ‒ Press engine/gearbox forwards carefully.

Note:

Do not damage P.A.S. pipe when moving engine/gearbox assembly.

• ‒ 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.
• ‒ Lower gearbox slightly and incline to left via the spindles of the gearbox support 3282.

• ‒ → 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.
• ‒ When lowering the gearbox change position of gearbox using the gearbox support 3282 spindles.

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.
• ‒ → Bolt support rail VW 457/1 to both pendulum support securing holes on subframe.

• ‒ Spacers totalling 6 mm must be inserted between subframe and support rail VW 457/1.

-A- Qty. 2 hexagon bolts M 8 x 25

• ‒ Fit support 3300 A and secure (arrows).

→ Vehicles with 5 valve engine

• ‒ The support 3300 A must sit on the threaded boss on the engine.

Continuation for all vehicles

• ‒ Press engine forward carefully.

Note:

Do not damage P.A.S pipe.

• ‒ 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.

• ‒ 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.
• ‒ Incline gearbox to left via the spindles of the gearbox mounting 3282.

• ‒ Insert gearbox.

Note:

Do not damage P.A.S pipe.

• ‒ Install lower engine/gearbox securing bolts and tighten to torque =>table, page 34-85 .
• ‒ → Remove support 3300 A (arrows).
• ‒ Then remove bolts -A- and remove support rail VW 457/1.

• ‒ Install upper engine/gearbox securing bolts and tighten to torque =>table, page 34-85 .
• ‒ → Fit gearbox console -A- with new bolts (arrows) and tighten to torque setting .

• ‒ Align engine/gearbox in installation position.
• ‒ → Install new hexagon bolts (arrows -B-) for left-hand assembly mounting in gearbox mounting and tighten to torque setting .
• ‒ Fit gearbox support (arrows -A-) to gearbox and tighten to torque setting .

• ‒ → Install lower engine/gearbox securing bolt (arrow A) and tighten to torque setting .
• ‒ Install pendulum support (arrows).

=> Running gear, axles, steering; Repair group 40

• ‒ Use new bolts for securing.
• ‒ Reconnect exhaust system.

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

• ‒ Install the retainer for the power-assisted steering pipe on starter and on gearbox.

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

=> Running gear, Axles, Steering front and four-wheel drive; Repair group 40; Servicing drive shafts

• ‒ If it was removed install protective cap for right-hand inner constant velocity joint to engine.

=> Running gear, axles, steering; Repair group 40; Servicing front suspension; Removing and installing swivel joint

• ‒ Install starter.

=> Electrical system; Repair group 27; Starter motor; Removing and installing starter motor

• ‒ → Install slave cylinder and tighten bolts to torque setting => Page 30-12 , item 13 .

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

Gearboxes up to 05.99

• ‒ → Install gear selector cable -B- and balance weight -A- on gear selector lever.
• ‒ Fit gate selector cable on follower/relay lever -C- to do this lift lug in direction of arrow.

• ‒ → Attach reversing light connector (arrow 2). Attach all other electrical connections and earth wires to gearbox and to the engine/gearbox securing bolts.

• ‒ Attach connector to speedometer sender (arrow 1).

• ‒ Then assemble air intake duct

=> Repair group 24; Servicing injection system

• ‒ Reconnect earth strap to battery.

Note:

Note radio coding for vehicles with coded radio.

• ‒ Checking gearbox oil .
• ‒ Adjusting gear selector mechanism => Page 34-24 .
• ‒ Install engine cover.
• ‒ Install insulation tray below engine/gearbox, if fitted.

Gearboxes from 05.99

• ‒ → Fit gear selector cable -B- with gearbox selector lever (arrow).
• ‒ Fit gate selector cable -A- with relay lever and secure (arrow).

• ‒ → Attach reversing light connector (arrow 2). Attach all other electrical connections and earth wires to gearbox and to the engine/gearbox securing bolts.

• ‒ Attach connector to speedometer sender (arrow 1).

• ‒ Then assemble air intake duct

=> Repair group 24; Servicing injection system

• ‒ Reconnect earth strap to battery.

Note:

Note radio coding for vehicles with coded radio.

• ‒ Checking gearbox oil .
• ‒ Adjusting gear selector mechanism => Page 34-52 .
• ‒ Install engine cover.
• ‒ Install insulation tray below engine/gearbox, if fitted.

Tightening torques

Gearbox to engine

→ Vehicles with 4-Cyl. engine

     1)     Also starter to gearbox

     2)     Only on engines with an aluminium sump,

     3)     Large cover plate for flywheel only on engines with heat steel sump (sump painted black)

     4)     Small cover plate for flywheel

Items A + B - Dowel sleeves

→ Vehicles with 5 and 6-Cyl. engine

     1)     Also starter to gearbox

     2)     Only on engines with an aluminium sump, on some engines M 10 x 50 bolts are fitted, the tightening torque is 25 Nm.

     3)     Flywheel cover plate only on engines with a sheet steel sump (sump painted black)

Items A + B - Dowel sleeves

Continuation for all vehicles

• ‒ Renew bolts

→ Gearbox to body

→ Rear gearbox mounting

• ‒ Renew bolts

Pendulum support to subframe and gearbox (bolts -A- and -B-)

=> Running gear, axles, steering; Repair group 40

Note:

Install engine/gearbox mountings stress-free.

=> Repair group 10; Removing and installing engine.

Selector mechanisms up to 05.99

Selector cable support bracket to gearbox => page 34-5 , item 14

Selector mechanisms from 05.99

Selector cable support bracket to gearbox => page 34-41 , item 9