Volkswagen Workshop Service and Repair Manuals

Removing and installing gearbox Required tools → Chapter Installing → Anchor Torque settings → Chapter –  Disconnect battery earth strap → Vehicle electrics; Rep. Gr.27. –  Remove battery. –  Remove battery carrier. –  Remove engine cover.

–  Also remove complete air filter. –  Pull intake hose -1- and connector -2- off air mass meter. –  Pull off vacuum hose -3-. –  Then remove bolts -4- and -5-. –  Remove complete air filter. –  Disconnect speedometer connector at gearbox.

–  Pull off electrical connections -1- through -4-. 1 -  To solenoid valves 2 -  To vehicle speed sender -G68- 3 -  Multifunction switch -F125- 4 -  Gearbox speed sender -G38- There are two versions of the gearbox speed sender -G38-, with and without cable. –  Remove wiring loom from retainer on gearbox and place to the side. –  Also remove retainer for power steering pressure line together with retainer for wiring harness. –  Move selector lever to “P” position.

–  Remove securing clip -3- from support bracket. –  Pull selector lever cable -1- from selector shaft lever -4-. –  Lay selector lever cable to side.

–  Remove earth cable -1- from engine/gearbox connecting bolt. –  Disconnect electrical connections -3- and -4- on starter. –  Separate connector -2- and pull out of retainer. –  Remove wiring harness retainer from starter. –  Remove upper starter motor bolt.

–  Clamp off and remove → ATF cooler hoses. –  Seal connections with clean plugs. –  Remove all upper engine/gearbox connecting bolts.

–  Fit support device -10 - 222 A- with legs -10 - 222 A /1- and support engine with gearbox in this position. –  Remove front left wheel bolts. –  Raise vehicle. –  Remove left wheel.

–  Remove “insulation”.

–  Remove left noise insulation. Only for vehicles with TDI engine –  Remove pressure pipe between charge air cooler and turbocharger. Continuation for all vehicles –  Remove right noise insulation.

–  Remove shield.

–  Remove bracket -1- for power steering pressure pipe from lower starter bolt -arrow-. –  Remove lower starter bolt. –  Remove starter -2-. Vehicles with 1.4 l engine –  Pull Lambda probe connector -3- out of retainer -4-. –  Remove retainer from gearbox. Continuation for all vehicles –  Remove shield for right inner constant velocity joint, if fitted, from engine. –  Unbolt drive shafts from gearbox. –  Raise right drive shaft and secure. Cable ties are appropriate because they will not damage the drive shaft.

–  Remove pendulum support. –  Unclip cover for torque converter nuts.

–  Remove nuts “Qty. 3” from torque converter -arrow-. –  To do this, turn crankshaft 120° for each bolt. Vehicles with 1.4 l engine –  Here, loosen torque nuts through hole above right drive shaft. Continuation for all vehicles –  Turn steering to left lock.

–  Mark installation position of suspension link bolts on swivel joint and remove bolts. –  Remove suspension link -arrow-.

–  Separate left coupling rod -1- from suspension link and turn coupling rod upwards. –  Swing wheel bearing housing outwards. –  Guide left drive shaft -2- out between subframe and gearbox. –  Raise drive shaft and secure. Cable ties are appropriate because they will not damage the drive shaft.

–  Remove bolts from left assembly mounting -2-. –  Carefully tilt engine and gearbox. To do this, lower left spindle about 60 mm.

–  Unbolt left bracket -1- from gearbox. –  Separate exhaust system behind front pipe.

–  Bolt on support rail -VW 457- at the two threaded holes for → pendulum support. –  Insert several washers between subframe and rail. Total thickness must be at least 6 mm. -A- Bolts → M8x25 –  Position engine support -3300 A- and secure with bolt -B-. Vehicles with 1.4 l engine –  Position engine support -3300 A- between gearbox and exhaust system. Continuation for all vehicles –  Tilt engine and gearbox forwards.

–  Set up gearbox support -3282-. The symbols on the adjusting plate -3282/2- indicate the supports required.

–  Move engine and gearbox jack -V.A.G 1383 A- under gearbox and support gearbox.

–  Set pin of safety support against oil sump and secure to gearbox housing.

–  On vehicles with triple roller drive shafts, turn drive flange to right so that the flat is vertical. –  Remove lower engine/gearbox connecting bolts. –  Press gearbox slightly off engine while simultaneously pressing torque converter out of drive plate. –  Press torque converter against → ATF pump. –  Lower gearbox slightly. –  When doing this, guide power steering pressure line past gearbox. –  Tilt gearbox using spindle of gearbox support -3282- and, whilst lowering, guide cover on wheel housing side closely past wheel housing.

–  Always ensure that right drive flange does not strike against engine, nor multifunction switch against subframe. –  Secure torque converter to prevent it from falling out. To raise gearbox, use a workshop hoist → Chapter. Installing gearbox –  Before installing gearbox in reverse order, note the following points: t  The starter bush can be renewed as necessary → Chapter. t  Check for proper seating of both dowel sleeves between engine and gearbox. t  The torque converter must be properly installed; it must not have slid forwards. There are different versions of the torque converter which must not be mixed up. For further information about the torque converter → Chapter. t  Check for proper seating of intermediate plate, if one is present.

t  It must be possible to guide the engine and gear box together by hand until the flanges make contact all around. t  If this is not so, then “something is wrong”! t  Readjust the gearbox support until the engine and gearbox “are aligned with each other”. t  Guide selector lever cable as soon as possible into its support bracket. t  Align engine and gearbox mountings free of tension → Engines; Rep. Gr.10. t  Torque settings → Chapter. t  Always renew securing clip of selector lever cable on support bracket of gearbox. The selector lever cable must always be adjusted → Chapter. t  After installing, check → ATF level → Chapter. t  After installation, perform basic setting → Chapter.