Manual Transmission/Transaxle: Service and Repair

W/012 5 SPEED TRANSMISSION

1. Disconnect battery ground cable.
2. Remove 3 upper engine/transmission bolts.
3. Remove transmission ground strap from transmission.
4. Disconnect speedometer connector.
5. Disconnect front exhaust pipe.
6. Remove rear crossmember, shift rod, bellhousing cover plate, and drive shaft protection plate.
7. Disconnect axle shafts at transmission, turn steering wheel to right lock, then tie axle shafts to body of vehicle to secure.
8. Remove clutch slave cylinder.
9. Remove steering bracket.
10. Support engine with tool 10-222A or equivalent. Support transmission with tool V.A.G. 1383 or equivalent.
11. Remove transmission strut at left rear, then remove front engine mount.
12. Remove remaining engine to transmission bolts, then lower transmission out of vehicle.
13. Reverse procedure to install, noting the following:
a. When reinstalling clutch slave cylinder, press it in using a lever until bolt can be installed easily.
b. Torque transmission to engine bolts as follows: (M8) to 18 ft.lbs., (M10) to 33 ft.lbs., and (M12) to 48 ft.lbs.
c. Torque drive shaft to flange bolts as follows: (M8) to 33 ft.lbs. and (M10) to 59 ft.lbs.

W/01A 5 SPEED TRANSMISSION

1. Disconnect battery ground strap.
2. Remove 3 upper engine/transmission bolts.
3. Disconnect ground strap from transmission.
4. Disconnect speedometer sensor, multifunction switch, oxygen sensor, and oxygen sensor heating element.
5. Remove engine protection plate.
6. Disconnect exhaust pipe from manifold, then separate exhaust pipe behind catalyst and remove both pipe and catalyst.
7. Remove drive shaft.
8. Remove rear crossmember.
9. Remove shift rod securing bolt at transmission and let shift rod hang.
10. Remove transmission cover plate.
11. Remove right axle shaft shield.
12. Disconnect axle shafts at transmission, turn steering wheel to right lock, then tie axle shafts to body of vehicle to secure.
13. Remove clutch slave cylinder.
14. Remove tie rod coupling from steering rack and turn wheels to the left.
15. Support engine with tool 10-222A. Support transmission with tool VW 1383.
16. Remove transmission strut at left rear and front engine mount.
17. Remove heat shield from bonded rubber bushing, bonded rubber bushing support bracket from transmission, then remove the bushing.
18. Remove seatbelt tensioning cable guide bolt from at left rear of transmission. Position guide and cables aside.
19. Lower right rear subframe by loosening mounting bolts.
20. Remove remaining engine to transmission bolts, then lower transmission out of vehicle.
21. Reverse procedure to install, noting the following:
a. When reinstalling clutch slave cylinder, press it in using a lever until bolt can be installed easily.
b. Torque transmission to engine bolts as follows: (M8) to 18 ft.lbs., (M10) to 33 ft.lbs., and (M12) to 48 ft.lbs.
c. Torque drive shaft to flange bolts to 33 ft.lbs.
d. Torque subframe mounting bolts to 25 ft.lbs., then tighten an additional 1/4 turn.
e. Torque driveshaft to transmission and final drive bolts to 40 ft.lbs.
f. Torque tie rod coupling to steering rack bolts to 33 ft.lbs.