Volkswagen Workshop Service and Repair Manuals

Removing gearbox; Golf 2004 and Golf Plus 2005 1.9 l - 77 kW - TDI engine

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Adjustment plate -3282/59-

t	Adapter -10 - 222 A /8-

t	Gearbox support -3282-

t	Insert tool, 18 mm -T10179-

t	Socket -T10061-

Special tools and workshop equipment required

t  Adapter -10 - 222 A /18-

t  Golf Plus only: wing support -T10311- t  Not illustrated: Engine and gearbox jack -V.A.G 1383 A- Brief description The gearbox is removed downwards separately, without engine. »From above« Remove battery, air filter and starter. »From below«: Remove noise insulation beneath engine, lower cover in front left wheel housing and pendulum support. Removing: –  Raise vehicle. All 4 supports of lifting platform must be at same height. –  Move selector lever to position »P« position. Only in vehicles with stub shafts   Note After loosening centre bolt, do not lower vehicle to ground again.

–  Step on the brake pedal while a 2nd mechanic loosens the two drive shaft bolts -arrow-. –  Remove both front wheels. Continuation for all vehicles –  Remove engine cover from cylinder head. –  Remove complete air filter housing → Rep. gr.24.

–  Remove battery and -battery tray- → Rep. gr.27. –  Remove starter → Electrical system; Rep. gr.27.

–  Remove selector lever cable from ball head, remove securing clip. A securing clip which has been removed is not allowed to be installed again. The clip will have lost its internal tension and so it might fall off. –  Therefore, when installing, always use a »new« securing clip. Remove cable with great care from cable support bracket on gearbox. Do not bend it. Cable may also be pushed slightly backwards out of cable support bracket and removed later when gearbox is lowered. But then observe cable when lowering gearbox.

–  Release mechatronic unit connector by pulling and pull off connector. –  Now remove all upper connecting bolts between engine and gearbox. –  Remove noise insulation → Rep. gr.50. –  Remove front part of wheel housing → Rep. gr.66. Only in vehicles with stub shafts –  Remove both drive shafts → Running gear, axles, steering; Rep. gr.40. Only in vehicles with flange shafts

–  If fitted, remove the heat shield over the right-hand drive shaft. Tightening torque → Rep. gr.40

–  Unbolt left suspension link from suspension strut. –  Swing left drive shaft into wheel housing onto longitudinal member. This will keep the shaft out of the way during further work. The surface protection of the shafts must not be damaged. Plastic cable ties or a pair of tensioning straps -T10038- are therefore very good for this.

Secure both drive shafts to suspension struts using tensioning straps -T10038-.

–  Remove right flange shaft of gearbox using socket -T10107 A-. Bolt has a 6 mm hexagon socket. Bolt can also be removed and installed with socket -V.A.G 1669-.

–  Screw 2 bolts into flange and counterhold flange shaft with a lever in order to remove and install flange shaft. –  Remove flange shaft with compression spring. –  Close opening in drive shaft using a suitable plug. –  To install flange shaft, if necessary press against gearbox with a lever and screw in bolt. Torque setting 30 Nm Continuation for all vehicles

–  Remove all retainers and brackets from front of gearbox.

–  Remove pendulum support. –  If there are hose and cable connections in area of engine support eye for support bracket -10-222A-, remove these now. –  Remove filler pieces from upper edges of both wings.

Golf Plus only: –  Use wing supports -T10311- on both sides. The supports prevent the weight of the engine from damaging the wings.

–	Support engine and gearbox. Do not raise.

Remove all bolts -1- and -2- for bracket. –  Then lower engine and gearbox slightly using spindles of support bracket -10 - 222 A- so that bracket can be removed. At most, 5 turns are sufficient to remove bracket. In many cases, the spindle does not need to be lowered further for the later removal of the gearbox. –  Set up gearbox support -3282- with adjustment plate -3282/59-.

–  Move engine and gearbox jack -V.A.G 1383 A- under gearbox and support gearbox. Do not raise. –  Position plate of pin under gearbox housing, not under mechatronic unit. –  Screw a pin into »rear« hole for pendulum support. The gearbox is separated from the engine in this position. –  Remove remaining engine/gearbox connecting bolts. –  Press gearbox off engine, »observing selector lever cable« and lower gearbox.

In some cases, there are retainers on the front of the gearbox. –  Remove retainers if installing a »new« gearbox, because there are no retainers on a »new« gearbox. Gearbox with flange shafts, torque setting → Chapter Bolt has a 6 mm hexagon socket. Bolt can also be removed and installed with socket -V.A.G 1669-.

–  Renew needle bearing in crankshaft → Rep. gr.13. Installing gearbox → Chapter.