Manual Transmission/Transaxle: Service and Repair

1. Disconnect battery ground cable located under rear seat.
2. Disconnect RPM sensor.
3. Remove upper engine to transmission attaching bolts.
4. Unscrew speedometer cable using wrench 3016 or equivalent or pull cable off sender.
5. On turbo models, unscrew cover plate, but do not remove.
6. Remove clip from clutch slave cylinder, drive out spring pin, then remove clutch slave cylinder leaving hydraulic line connected.
7. Tie up coolant hoses and cable, then install engine supporting fixture 10-222 A or equivalent to support engine.
8. Remove bracket, then the clutch cover plate.
9. Disconnect axle shaft and right transmission bearing cover plates.
10. Disconnect transmission mounting and exhaust pipe.
11. Remove driveshaft, then the hoses from vacuum servo.
12. Disconnect right axle shaft, then remove starter.
13. On turbo models, remove cover plate.
14. Remove front exhaust pipe, then support transmission using transmission lift VW 1383 or equivalent.
15. Remove tension cable bracket, then push tensioning system cable and bracket off of retainer. Retainer can only be removed with transmission out of vehicle.
16. Disconnect left transmission mounting and left axle shaft.
17. Press shift rod and adjusting rod off of ball joints, then remove push rod from transmission.
18. Remove side transmission mounting bolts, then push transmission back.
19. Disconnect plug connection to transmission, then lower transmission carefully.
20. Reverse procedure to install, noting the following:
a. Ensure engine and transmission mounts are aligned and free of tension.
b. Clean mainshaft splines and lightly coat with MoS2 grease or equivalent.
c. When installing push rod, ensure shift lever bracket bearing pin is inserted into rubber block.
d. Tighten nuts and bolts to specifications.