Volkswagen Workshop Service and Repair Manuals

Removing gearbox –  Check whether a coded radio is fitted. If so, obtain anti-theft code. –  Remove complete air filter housing if it is over the gearbox → Rep. gr.23 or → Rep. gr.24 –  Remove battery, battery cover and battery tray → Electrical system; Rep. gr.27. –  If the lifting eyes of the engine for support bracket -10 - 222 A- are covered by a component, for example the air filter, it must be removed now. → Rep. gr.23 or → Rep. gr.24. –  Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -B-.

–  Pull gear selector cable off pin. –  Remove relay lever -A- together with cable end-piece → Fig.. –  Remove gearbox selector lever -B- by removing nut -arrow 2-.

–  Remove cable support bracket from gearbox -arrows-. –  Then raise and secure gear selector cable and gate selector cable.

–  Pull line between master and slave cylinders -A- out of support -B-, if present, on gearbox. –  Remove slave cylinder -arrows-, lay to side and secure. Do not disconnect pipes.   Caution Do not operate clutch pedal any more.

–  Gearboxes for vehicles with start-stop system: pull connector -arrow- from gearbox neutral position sender -G701-. –  Remove cables from starter → Electrical system; Rep. gr.27. –  Then remove upper securing bolt for starter. –  Remove upper engine/gearbox connecting bolts. –  Remove foam pieces or seal from upper edge of left and right wings → Body, front; Rep. gr.50.

–  Set up support bracket -10-222 A- behind bonnet support. –  Use: t  Adapter -10 - 222 A /8- t  Tensioning strap -T10038- –  Position both adapters -10 - 222 A /8-: l  Directly in front of plenum chamber cover -arrow-.

–  Please pay attention to paint on edges -arrows-. –  Secure both adapters -10 - 222 A /8- with tensioning belts -T10038-. l  Tensioning belts must be guided past bonnet hinge/body as close as possible to bolted connection. –  Take up weight of engine/gearbox assembly on spindles.

–  Remove noise insulation tray below engine and gearbox → General body repairs, exterior; Rep. gr.50. –  Pull connector -1- off reversing light switch -F4-. –  Remove retainer -2- from starter -arrow- and remove wiring retainer from gearbox, if present. –  Remove starter → Electrical system; Rep. gr.27.

–  Remove cover plate -arrows-.

–  Remove pendulum support -arrows A- and -B-. –  Disconnect exhaust system from subframe → Rep. gr.26. –  Disconnect coupling rod -1- from anti-roll bar on both sides → Running gear, axles, steering; Rep. gr.40.

–  Press anti-roll bar upwards.

–  Remove drive shaft heat shield, if present -arrows- → Running gear, axles, steering; Rep. gr.40. –  Unbolt drive shafts from gearbox flange shafts and tie up as high as possible → Running gear, axles, steering; Rep. gr.40.

–  Check to see if a cover plate -A- is installed above the right flange shaft. –  Remove cover plate -arrows-.

–  Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting. –  Tilt engine and gearbox assembly by lowering spindles of support bracket -10-222 A-.   Note When lowering engine and gearbox assembly, ensure that gearbox does not contact subframe in region of differential. l  Securing bolts -arrows- for gearbox bracket -A- must be accessible.

–  Remove gearbox bracket -A--arrows-. –  Assemble engine and gearbox support, gearbox support -3282-, adjustment plate -3282/31- for „02T“ gearbox and mounting elements as follows: –  Fit adjustment plate -3282/31- on gearbox support -3282- (adjustment plate fits in only one position). –  Align arms of gearbox support according to holes in adjustment plate.

–  Screw in support elements -A- as illustrated on adjustment plate.

–  Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel. –  Align adjustment plate parallel to gearbox and lock safety support on gearbox. –  Remove engine/gearbox connecting bolt -arrow-.

–  Remove engine/gearbox connecting bolt -A- in area of right flange shaft.   Note On some engines, the engine/gearbox connecting bolt is below the right flange shaft. –  Press gearbox off dowel sleeves and carefully swing towards subframe. –  Have a second mechanic press engine forwards. –  When doing this, observe radiator. –  Turn gearbox downwards in vicinity of differential.

–  Then carefully lower gearbox. When doing this, guide with right-hand flange shaft -A- in area of flywheel and intermediate plate as shown and with left-hand flange shaft -B- in area of subframe. –  Push left wheel housing liner slightly to left in lower are so that the gearbox does not contact it. –  When lowering gearbox, change position of gearbox using spindles of gearbox support -3282-.   Note Observe lower connection for coolant hose between radiator and engine.