Transmission, Removing

Transmission, removing





Special tools and workshop equipment required
^ 10 222A Support
^ 10 222 A/1 Support
^ V.A.G 1383A Transmission jack
^ 3282 Transmission support
^ 3282/8 Adjustment plate
^ 3282/40 Pin (3x)
^ 3282/59 Support





Special tools and workshop equipment required
^ 3300 A Engine support
^ VW 457/1 Support rails
^ 3336 Transmission lifting beam
^ V.A.G 1331 Torque wrench
^ V.A.G 1332 Torque wrench





Support rails VW 457/1, modifying
- Support rails VW 457/1 are required to remove and install the transmission.
- To secure support rail VW 457/1 to the subframe, an additional hole is needed (arrow).
- Dimensions given are in mm.
- If hole is not already there: drill a hole (8.5 mm diameter - see arrow) in support rail VW 457/1.

Removing





- Unscrew bolts (arrows) and remove engine cover.

Notes: In the following work sequence the battery Ground strap must be disconnected. Check whether the car has a coded radio, and if so obtain the radio code first.

- With the ignition switched off, disconnect the battery Ground strap.





- Remove battery.
- Unscrew bolts (arrows) and remove battery tray.





- Release hose clamp -4- and disconnect intake hose and electrical connector-1 from air mass meter.
- Remove hose -5- from air filter housing.
- Unscrew bolts -2- and - 3 -, then remove air cleaner housing (complete).





- Remove cable support bracket from transmission (arrows). If necessary, unclip hose at cable support bracket first.





- Lever off gear selector cable -A- and gate selector cable -B- using an open-ended wrench -1 -.
1- 1-Standard open - ended wrench (13 mm), commercially available





- Lift selector cables clear and secure them in position.
- Remove transmission support (arrows A) from transmission.





- Remove slave cylinder, place to one side and secure with wire. Do not disconnect lines.





Notes: Do not depress clutch pedal.

- Remove cable retainer (arrow 1) on starter.
- Then remove upper securing bolt (arrow 2) on starter.
- Remove Ground strap from upper securing bolt between engine and transmission (arrow 3)
- Remove upper engine/transmission securing bolts.





- Pull connector off road speed sender (arrow 1).
- Pull off reverse light connector (arrow 2).
- If there are hoses and cable connections around the engine mounting eyes for support bar 10 222A, remove these now.
- Fit support bar 10 222A together with legs 10 222 A/1.





- Set up support bar on wheel housing panels (arrows).
- Take up the weight of the engine/transmission assembly on the spindles.





- Remove center and left parts of insulation tray (if fitted) below engine/transmission.
- Detach power steering pipe from transmission and pull speed nut off transmission.
- Remove starter.

- Remove right hand inner constant velocity joint protective cover (if fitted) from engine.
- Turn wheels fully onto left lock.





- Disconnect drive axles from drive flanges and tie up as high as possible. When doing so, do not damage painted surfaces.
- Remove flywheel small cover plate - A - behind the right - hand flanged shaft (arrows), if fitted.
- Remove lower flywheel cover plate (if fitted).





- Separate exhaust system and if necessary remove from subframe.





- Remove pendulum support (arrows A and B).
- Remove hexagon bolts (arrows B) from left hand - hand assembly mounting.

- Assemble transmission jack with transmission support 3282, adjustment plate 3282/8 for "02A" transmission and support elements as follows:
- Place adjustment plate 3282/8 on transmission support 3282. (Adjustment plate only fits in one position).





- Align arms of transmission support according to holes in adjustment plate.





- Bolt on support elements - A - as shown on adjustment plate.
- Place transmission jack under vehicle. Arrow symbol - B - (Illustration No. V34 -2670) on adjustment plate points to front of vehicle.
- Align adjustment plate parallel to transmission and lock safety supports on transmission.
- Remove lower engine/transmission securing bolts.





- Press transmission off dowel sleeves and carefully swing toward subframe.
- Lower transmission slightly and incline to left via the spindles of the transmission support 3282.





- Then lower the transmission carefully. When doing this, guide right - hand drive flange - A - in area of flywheel as illustrated and guide left - hand drive flange - B - in area of subframe.
- When lowering the transmission, change position of transmission using the transmission support 3282 spindles.

Notes: Do not damage power - assisted steering pipe when lowering transmission.