Volkswagen Workshop Service and Repair Manuals

Removing

• ‒ With the ignition switched off disconnect the battery earth strap.

Note:

Note radio coding for vehicles with coded radio.

• ‒ Remove radiator cover.
• ‒ → Remove front pipe -A- and rear pipe -B- for ventilating the propshaft bearing from fan (arrow 1), ABS unit (arrow 2) and from heat shield.

On vehicles with electronic speedometer:

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

• ‒ Pull off reverse light connector (arrow 2). Disconnect all other electrical connections and earth wires from gearbox and from the engine/gearbox securing bolts.

• ‒ → Remove balance weight -A- and gear selector cable -B- from gear selector lever.
• ‒ 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) and tie up, first unclip hose on cable support bracket if necessary.

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

Note:

Do not depress clutch pedal.

On vehicles with mechanical speedometer:

• ‒ Disconnect speedometer drive cable from gearbox with key 3016.

• ‒ Remove upper engine/gearbox securing bolts.
• ‒ Remove coolant system expansion reservoir and lay to one side. Do not open coolant system.
• ‒ → Remove hexagon bolt -A- from left-hand gearbox assembly mounting -B-.

• ‒ Remove suction hose and place to side.
• ‒ → Remove bolt (arrow) on right-hand engine console. First remove connector mounting plate -A-.

• ‒ Remove fan with cover and carrier plate.
• ‒ If fitted remove electrical connector securing plate from front console.
• ‒ → Remove bolt -A- for console -B- .

• ‒ → Fit support bar 10-222A together with legs 10-222 A/1.
• ‒ Take weight of engine/gearbox assembly on the spindles.

• ‒ Remove starter.

=> Repair group 27; Removing and installing starter.

• ‒ Remove power assisted steering pipe bracket from gearbox.
• ‒ Remove front console (bolt -A-).
• ‒ → Remove front engine mounting (bolt -B-).

• ‒ → Remove vibration damper -A- from sub-frame. Mark installation position.
• ‒ Separate exhaust system behind front exhaust pipe.

=> Repair group 26; Removing and installing parts of exhaust system, four wheel drive.

• ‒ Secure catalyst in lowered position.

• ‒ Mark position of propshaft with flexible coupling to bevel box flange.
• ‒ → Disconnect propshaft flexible coupling from bevel box flange (arrows).
• ‒ Push propshaft back onto stop.

Note:

When removing and installing the gearbox do not damage the seal in the propshaft flange.

• ‒ Disconnect drive shaft from gearbox.
• ‒ Remove air deflector from right-hand wishbone.

=> Running gear; Repair group 40

• ‒ Tie-up right-hand drive shaft forwards on wishbone.
• ‒ Tie-up left-hand drive shaft as high as possible,
• ‒ → Removing gearbox console -A- from gearbox.
• ‒ Push engine/gearbox assembly forwards (2nd mechanic required) and remove lower gearbox console securing bolt -B-.

Note:

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

• ‒ → Remove bevel box carrier from engine and bevel box (arrows).
• ‒ Place drip tray underneath.
• ‒ Remove cap by piercing cap centre with a screwdriver and levering out.
• ‒ Remove drive flange counter sunk head bolt with V.A.G 1669 or 6 mm socket insert (commercially available) and counter hold against turning with a drift.
• ‒ Pull drive shaft with drive flange out carefully and note spring behind drive flange.

• ‒ → Remove bevel box/engine support.
• ‒ Remove large clutch cover plate.

• ‒ → Remove small flywheel cover plate -A- located behind bevel box (arrows).
• ‒ Remove ribbed V-belt cover from body, front right.
• ‒ Push engine/gearbox assembly as far as possible to the right.
  Thereby ensuring sufficient clearance between P.A.S. pipes and drive unit.

Removal position:
Power unit crankshaft belt pulley lies almost against right-hand longitudinal member.

• ‒ Remove bevel box/gearbox securing bolts.
• ‒ Press bevel box off gearbox.

Note:

→ When removing and installing the bevel box do not damage the seal (arrow) in the propshaft flange.

• ‒ Take bevel box out downwards between assembly carrier and sump, to do this push engine/gearbox assembly forwards (2nd mechanic).

• ‒ Assemble gearbox jack V.A.G 1383A 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 with gearbox support 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 bolt ( , illustration V34-2743, item 2).

• ‒ Press gearbox off engine and lower carefully while pushing engine/gearbox assembly forward slightly and constantly correct the position via the gearbox jack spindles.

Notes:

• ◆ When lowering do not damage P.A.S. pipes.
• ◆ When lowering guide gearbox around engine carrier.
• ◆ When swinging out ensure sufficient clearance between gearbox connecting piece and clutch as well as between flange shaft or gearbox housing and assembly carrier.
• ◆ If the vehicle is to be moved with the propshaft detached then secure the propshaft to prevent damage.

• ‒ → Bolt gearbox lifting device 3336 to clutch housing.

• ‒ → Set support arm on sliding piece with locking pin (arrow).

No. of holes visible = 5

• ‒ Take gearbox out with workshop crane and gearbox lifting device 3336
• ‒ Place gearbox down.

Installing

Installing gearbox is carried out in the reverse sequence. When installing gearbox ensure engine/gearbox mountings are installed stress-free.

=> Repair group 10; removing and installing engine.

Notes:

• ◆ → When replacing gearbox, always transfer the senders for speedometer (illustration), gear selector and relay lever to new assembly if available.
• ◆ Clean input shaft splines and lightly grease with G000 100 grease.

• ◆ Check whether dowel sleeves for aligning engine/gearbox are fitted in cylinder block, install if necessary.
• ◆ When replacing the gearbox ensure that the intermediate plate is correctly positioned.
• ◆ → 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.

• ◆ Build bevel box on as follows:

• ‒ → Always replace sealing ring to seal bevel box/gearbox (arrow A) and sealing rings to seals sleeves for the oil supply system (arrow B and C), lightly coat with oil.
• ‒ Push bevel box completely onto gearbox, thereby ensuring that the bevel box input shaft teeth are guided centrally onto the differential connecting piece.
• ‒ If the teeth position and the central guide are correctly set then the bevel box will slide onto the stop against the gearbox.
• ‒ Do not pull the bevel box onto the gearbox using securing bolts otherwise the bevel box will cant and the securing eyes can break off.

• ◆ → When installing the gearbox carrier note following assembly sequence:
• ‒ Tighten all bolts hand-tight.
• ‒ Tighten bolts -A- to torque setting.
• ‒ Tighten bolts -B- and -C- to torque setting.

• ◆ When removing and installing do not damage seals in propshaft flanges.
• ◆ Renew propshaft if damaged.
• ◆ Push propshaft horizontally onto guide pins.
• ◆ Replacing drive shaft seal.

=> Running gear; Repair group 40; Servicing drive shaft

• ◆ Installing front exhaust pipe to catalyst

=> Repair group 26; Removing and installing parts of exhaust system, four wheel drive

• ◆ Installing starter/wiring.

=> Repair group 27; Removing and installing starter.

• ◆ Checking oil in gearbox with bevel box .
• ◆ Adjust gear change linkage => Page 34-19 .

Tightening torques

→ Gearbox to engine

     1)     Also starter to gearbox

     2)     Flywheel large cover plate

     3)     Flywheel small cover plate

Pos. A + B - Dowel sleeves

→ Assembly mountings