Manual Transmission/Transaxle: Service and Repair

NOTE: On air bag equipped vehicles, refer to Air Bags (Supplemental Restraint Systems), Service Precautions. Also refer to Air Bag(s) Arming and Disarming.

1. Vehicles with audio coded antitheft system refer to Radio/Stereo, Service Precautions.
2. Disconnect battery ground cable located under rear seat.
3. Remove front wheels, then the cross brace to suspension strut domes.
4. Remove complete air filter/duct assembly. Detach lower housing, position rearward, then pull up and out.
5. Remove bracket for ignition wires and discard bolts.
6. Remove bolt for engine harness support bracket, then all wiring retainers from transmission.
7. Remove upper engine to transmission attaching bolts, then the bolts for right engine mount.
8. Remove engine lower cover, then the crossmember.
9. Remove front exhaust pipe with catalytic converter, then the transmission heat shield.
10. Remove driveshaft heatshield, then the driveshaft.
11. Remove bolts for transmission mounts, then install engine support 10-222A or equivalent and raise engine slightly.
12. Remove axle shaft shields, then disconnect axle shafts from transmission and position on subframe.
13. Disconnect pressure line from pressure hose at clutch slave cylinder and plug hydraulic openings. Slave cylinder remains on transmission.
14. Disconnect front/rear shift rods and push rods, then disconnect electrical connector from backup light switch.
15. Disconnect speedometer sensor electrical connector, then remove cable guide for seat belt tensioning system. Position guide/cable out of way.
16. Disconnect oil pressure supply line from oil pump, then the front/rear oil pressure return lines and plug hydraulic openings.
17. Disconnect oil pressure supply and return lines at A/C compressor.
18. Remove remaining engine to transmission mounting bolts, except bottom three.
19. Support subframe with transmission jack and adapter Nos. VAG 1383/ and VAG 1584 or their equivalents.
20. Remove subframe mounting bolt and lower subframe carefully to provide adequate clearance, then tie subframe to body.
21. Secure axle shafts to subframe, then ensure radiator fan turns without interference.
22. If radiator fan does not turn freely, loosen engine mount slightly and check again.
23. Support transmission with transmission jack and adapter Nos. VAG 1383/ and VAG 1584 or their equivalents.
24. Remove transmission right and left mounts along with transmission support.
25. Remove remaining engine to transmission mounting bolts, then push transmission back and remove from vehicle.
26. Reverse procedure to install, noting the following:
a. Prior to installation of transmission, remove slave cylinder and reinstall after transmission installation.
b. Install engine/transmission mountings without tension.
c. Clean grease and corrosion from driveshaft splines and lubricate with a thin coating of G 000 100 or equivalent.
d. Ensure dowel sleeves are present in cylinder block, replace if necessary.
e. Bleed hydraulic clutch system, refer to Transmission and Drivetrain, Clutch System Bleed.
f. Lubricate crankshaft bearing with MoS2 grease or equivalent.
g. When installing push rod, ensure shift lever bracket bearing pin is inserted into rubber block.
h. Inspect gearshift lever/linkage adjustment and adjust if necessary.
i. Tighten nuts and bolts to specifications.