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
• ◆ 3282 Gearbox support
• ◆ 3282/31 Adjustment plate
• ◆ 3282/48 Pins (Qty. 2)
• ◆ 3282/59 Support
• ◆ 3336 Gearbox lifting beam

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

• ◆ V.A.G 1331 Torque wrench
• ◆ V.A.G 1332 Torque wrench
• ◆ V.A.G 1383 A Engine/gearbox jack

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 air cleaner.

=> Repair group 24; Servicing injection system; Removing and installing parts of injection system

• ‒ → Remove gear selector cable securing clip -1- from gear selector lever -A-.
• ‒ Remove gate selector cable securing clip -2- from relay lever -B-.
• ‒ Pull gate selector cable and gear selector cable off pin.

Remove relay lever and gear selector lever from gearbox as follows:

• ‒ → Select 2nd gear with gear selector lever -A-, to do this push gear selector lever in direction of arrow -1- and then in direction of arrow -2-.

• ‒ → Pull securing clip -arrow 1- off relay lever -B-.
• ‒ Pull relay lever -B- slightly off guide (towards engine) until the sliding block -C- is free.
• ‒ Then swing relay lever in direction of arrow -3- and remove.
• ‒ Remove gear selector lever -B- by removing nut -arrow 2-.

• ‒ → Remove cable support bracket from gearbox (arrows).
• ‒ Then tie gear selector cable and gate selector cable up.
• ‒ Pull pipe/hose assembly -A- out of bracket -B- on gearbox.
• ‒ Remove slave cylinder -C-, place to one side and secure with wire. Do not disconnect pipes.

Note:

Do not depress clutch pedal.

• ‒ Unclip speedometer sender wiring from gearbox.
• ‒ Remove engine/gearbox upper securing bolts.
• ‒ Then remove upper securing bolt on starter.
• ‒ If there are hoses and cable connections in area of engine mounting eye for support 10-222A, remove these now.

• ‒ → Fit support bar 10-222A together with legs 10-222 A1.
• ‒ Take weight of engine/gearbox assembly on the spindles.
• ‒ Raise vehicle.
• ‒ Remove centre and left part of insulation tray below engine/gearbox.
• ‒ Remove power assisted steering pipe clamp from gearbox console.

• ‒ → Pull off reversing light connector -1-.
• ‒ Remove retainer -2- on starter -arrow B-.
• ‒ Remove earth strap at engine/gearbox securing bolt -arrow A-.
• ‒ Remove starter.

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

• ‒ Remove right hand inner constant velocity joint protective cover from front exhaust pipe.

• ‒ Separate exhaust system after front exhaust pipe at double clamp.

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

• ‒ → Unbolt front exhaust pipe bracket on subframe -arrows- and unhook.
• ‒ Disconnect drive shafts from flanged shafts and tie up as high as possible, when doing this do not damage surface protection.

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

• ‒ Remove engine/gearbox securing bolt -A- above right-hand flanged shaft.

• ‒ → 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:

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

• ‒ → Remove gearbox console -1-, to do this remove bolts -A- and -B-.
• ‒ Remove engine/gearbox connecting bolts in area of oil sump (bolts remain in engine).
• ‒ Assemble gearbox jack with gearbox support 3282, adjustment plate 3282/31 for "02T" gearbox and support elements as follows:
• ‒ Place adjustment plate 3282/31 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 A34-0349, Page 34-35 ) on adjustment plate points to front of vehicle.
• ‒ Align adjustment plate parallel to gearbox and lock safety supports on gearbox.
• ‒ Remove engine/gearbox connecting bolt (arrow).
• ‒ Press gearbox off dowels and carefully swing towards subframe.
• ‒ Ensure that the intermediate plate is correctly positioned on engine.
• ‒ Press engine forwards carefully with the help of a second mechanic.
• ‒ Take note of radiator.
• ‒ Tilt gearbox downwards in area of differential.

• ‒ → Then lower gearbox carefully. When doing this, guide right-hand flanged shaft -A- in area of flywheel/intermediate plate as illustrated and guide left-hand flanged 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 beam 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

Note:

→ If the gearbox has been replaced,the bracket -1- for the pendulum support on clutch housing must always be transferred to new component. The curvature -arrow A- faces forwards.

Torque settings for bolts -arrows- , item 6 .

• ‒ 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.
• ‒ The threads of all threaded holes, in which self-locking bolts are screwed, should be cleaned of locking fluid remains using a thread cutter.
• ‒ Assemble gearbox jack with gearbox support 3282, adjustment plate 3282/31 for "02T" gearbox and support elements as follows:
• ‒ Place adjustment plate 3282/31 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 parallel to gearbox and lock safety supports on gearbox.
• ‒ Place gearbox jack under vehicle, arrow symbol -B- (=> Illustration A34-0349, Page 34-38 ) on adjustment plate points to front of vehicle.

• ‒ Tilt gearbox downwards via the spindles of gearbox support 3282 in area of differential.

• ‒ Have second mechanic carefully press engine forward.

• Take note of the radiator when doing this.

• ‒ → Then lower gearbox carefully. When doing this, guide right-hand flanged shaft -A- in area of flywheel/intermediate plate as illustrated and guide left-hand flanged shaft -B- in area of subframe.

Note:

Do not damage P.A.S pipe.

• ‒ Insert gearbox.

• ‒ Ensure that the intermediate plate is correctly positioned on engine.
• ‒ → Install engine/gearbox securing bolt (arrow) and tighten to torque =>table, page 34-45 .
• ‒ Install lower engine/gearbox securing bolts and tighten to torque =>table, page 34-45 .
• ‒ Remove gearbox jack from gearbox after gearbox is bolted to engine.

• ‒ → Fit gearbox console -1- with new bolts -A- and -B- and tighten to torque setting .

Note:

Observe different length of securing bolts -A- and -B-.

• ‒ Align engine/gearbox in installation position. To do this tighten the left-hand spindle on support bar 10-222 A.

• ‒ → Use new hexagon bolts -arrows- when installing left-hand assembly mounting in gearbox mounting and tighten to tightening torque .

• ‒ Install upper engine/gearbox securing bolts and tighten to torque =>table, page 34-45 .

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

=> Running gear, axles, steering front and four-wheel drive; Repair group 40; Servicing front suspension; I - Assembly overview, subframe, anti-roll bar, wishbone

• ‒ Use new bolts for securing.

• ‒ → Install engine/gearbox connecting bolt -A- above right-hand flanged shaft and tighten to torque =>table, page 34-45 .

• ‒ Attach connector to speedometer sender (arrow).

• ‒ Fit drive shafts to gearbox.

=> Running gear, axles, steering front and four-wheel drive; Repair group 40; Servicing drive shaft; Removing and installing drive shaft

• ‒ → Hook front exhaust pipe on bracket and secure to subframe
  -arrows-.

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

• ‒ Reconnect exhaust system.

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

• ‒ Install protective cover for right-hand inner constant velocity joint to front exhaust pipe.

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

• ‒ Install starter.

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

• ‒ → Attach earth strap to engine/gearbox securing bolt -arrow A-.
• ‒ Install retainer -2- on starter -arrow B-.
• ‒ Reconnect reversing light connector -1-.
• ‒ Install pipe clamp for power-assisted steering pipe on gearbox console.

• ‒ Clip speedometer sender wiring onto gearbox.
• ‒ → Install slave cylinder -C- and tighten to torque => page 30-12 , item 12 .
• ‒ Push pipe/hose assembly -A- into bracket -B- on gearbox.
• ‒ Set up cable support bracket on gearbox and tighten bolts -arrows- to torque => page 34-11 , item 7 .

• ‒ → Install gear selector lever -A-.
• ‒ Tighten hexagon nut -arrow 2- to tightening torque => Page 34-13 , item18 .
• ‒ Select 2nd gear on gearbox selector lever -A- => Page 34-29 , Fig. N34-1587.
• ‒ Insert relay lever -B- into mounting on selector mechanism cover.
• ‒ When doing this swing relay lever, so that it engages with the sliding block -C- into gear selector lever guide.
• ‒ Secure relay lever with circlip -arrow 1-.

• ‒ → Spread a small quantity of polyurea grease on the pins of the gear selector lever -A- and the relay lever -B-.
• ‒ Always renew securing clips -1- and -2- after dismantling.
• ‒ Secure gear selector cable with securing clip -1- and gate selector cable with securing clip -2-.
• ‒ Install air cleaner.

=> Repair group 24; Servicing injection system; Removing and installing parts of injection system

• ‒ Reconnect earth strap to battery.

Note:

Note radio coding for vehicles with coded radio.

• ‒ Check gearbox oil .

Gear oil specification => Page 00-3

• ‒ Adjust selector mechanism => Page 34-21 .
• ‒ Install engine cover.
• ‒ Install noise insulation.

Tightening torques

→ Gearbox to engine

     1)     Also starter to gearbox

Item A - Centring sleeves

→ Gearbox console -1- to gearbox

• ‒ Renew bolts

→ Gearbox to body

• ‒ Renew bolts

Note:

Install engine/gearbox mountings stress-free.

=> Repair group 10; Removing and installing engine.