Removal/Installation

REMOVAL

CAUTION:
On vehicles equipped with an anti-theft radio, make sure you know the correct radio activation code before disconnecting the battery.


NOTE: If the transmission or the clutch housing is being replaced, refer to information about clutch housing modifications beginning with transmission number 13 09 3. Application and ID

- Disconnect battery Ground (GND) strap.
- Disconnect clutch cable.





- Disconnect Vehicle Speed Sensor (VSS) -arrow 1- and Back-Up Light Switch (F4) -arrow-
- Disconnect all other electrical connections and Ground leads from battery.
- Remove upper bolts connecting transmission and engine. 2-.





- Remove bolt -arrow- on right-side engine assembly support bracket.
- Where applicable, remove connector support plate -A-.





Cabrio Only
Engine support on body
Tightening torques:
Nuts -A-: 25 Nm (18 ft lb)
Bolt -B-: 50 Nm (37 ft lb)
Install spacers -C- before attaching support.

NOTE: A spacer plate that combines the spacers in a single unit is available as a replacement part.





All Vehicles
- Disconnect front of selector rod -A- and short selector rod -B- at gearshift shaft lever.





- Open clamp, then unhook long selector rod -C- at relay lever.





- Remove two upper bolts -arrows- from transmission bracket at left of transmission.





- If applicable, remove transmission support.
- Remove hex-head bolt -arrow 1- on left side of transmission assembly support.
- Remove nuts -arrow 2- on left side of transmission support.

NOTE:
^ The transmission support was gradually discontinued after approx. Nov. 1993 production.
^ When carrying out repairs on a vehicle that is equipped with the support, it should always be re-installed.





Cabrio Only
Transmission support on body
Tightening torques:
Bolt -A-: 50 Nm (37 ft lb)
Nuts -B-: 50 Nm (37 ft lb)





All Vehicles
- Remove bolt attaching front of bracket to engine mount.





- Attach engine sling 10-222A and adjust 10-222A/1 adapters to slightly take up engine weight.
- Where applicable, remove insulation shield beneath engine/transmission.
- Remove Starter, refer to Starting and Charging.
- Remove front bracket.





- Remove left-side engine mount attachment bolt (arrows).
- Remove large clutch shield.





- Remove small shield -arrows- behind right-side drive flange -A-.





- Remove third bolt -arrow- for transmission bracket at left and remove transmission bracket.
- Use left-side spindle to lower transmission.
- Remove bolts for left-side transmission support and remove it.
- Disconnect drive shaft from transmission, removing heat shield for inner joint from engine where necessary.
- Turn steering all the way to the left and suspend drive shafts as high as possible.





- Push engine/transmission assembly toward the front and around right-side assembly support.
- Assemble transmission jack with transmission support 3282 and adjustment plate 3282/2 and support components as follows:
- Place 3282/5 adjustment plate on 3282 transmission support.

NOTE:
^ Adjustment plate fits in one position only.
^ Adjust arms of transmission support to correspond to holes in adjustment plate.





- Bolt on support components -A- as illustrated on adjustment plates.





- Place transmission jack under vehicle.
- Arrow -B- on adjustment plate points toward front of vehicle (see illustration in previous step above).
- Align adjustment plate parallel to transmission and lock securing support on transmission.

NOTE: If transmission support 3282 is not available, the transmission can also be removed and installed using VAG 1383A transmission jack

- Remove lower bolt attaching engine to transmission.





- Press transmission away from alignment dowel pins and carefully lower.
- Guiding right drive flange -A- past flywheel.
- Guide left drive shaft -B- past assembly support.

CAUTION: When lowering the transmission, use care to avoid damaging power steering lines.

INSTALLING
- Install transmission in reverse order of removal sequence.
- Be sure to install engine/transmission mounts free of tension, also refer to Engine.

NOTE:
^ Clean clutch hub splines of transmission input shaft and apply a light coat of G 000 100 grease.
^ When installing transmission, ensure that intermediate plate is positioned correctly.
^ Check whether dowel pins for aligning engine with transmission are installed in engine block, and install where necessary.
^ Check transmission oil level.
^ Check operation of clutch cable automatic adjustment mechanism.
^ Adjust shift linkage. Adjustments
^ If the clutch housing has been replaced, or if the entire transmission is being replaced, refer to information about clutch housing modifications beginning with transmission number 13 09 3. Application and ID

- Tightening torques:





- Transmission To Engine:
Fastener No. 1
Quantity 2
Size: 12 x 55 mm
Tightening torque: 80 Nm (59 ft lb)
Fastener No. 2
Quantity 1
Size: 12 x 64 mm
Tightening torque: 80 Nm (59 ft lb)
Fastener No. 3 *
Quantity 2
Size: 10 x 140 mm
Tightening torque: 60 Nm (44 ft lb)
Fastener No. 4 **
Quantity 3
Size: 7x 12 mm
Tightening torque: 10 Nm (7 ft lb)
Fastener No. 5 **
Quantity 1
Size: 6x 8 mm
Tightening torque: 10 Nm (7 ft lb)

* Also starter and bracket at front of transmission
** Flywheel shield plate
A and B - Dowel pins






- Assembly Mounts:
Fastener No. 1
Quantity 1
Size 10 x 60 mm
Tightening torque: 45 Nm (33 ft lb)
Fastener No. 2
Quantity 1
Size 10 x 30 mm
Tightening torque: 60 Nm (44 ft lb)
Fastener No. 3 (1)
Quantity 1
Size 10 x 45 mm
Tightening torque: 60 Nm (44 ft lb)
Fastener No. 4 (1)
Quantity 2
Size 10 mm nut
Tightening torque: 40 Nm (30 ft lb)

(1) Not applicable to all vehicles. The transmission support was gradually discontinued after approx. November 1993 production. When carrying out repairs on a vehicle that is equipped with the support, it should always be re-installed.

- Transmission bracket (left) to transmission: 35 Nm (26 ft lb)
- Engine bracket right to subframe 60 Nm (44 ft lb)
- Engine mount to subframe: 50 Nm (37 ft lb)
- Drive shaft to drive flange: 45 Nm (33 ft lb)

Cabrio Only
- Engine support:
Nuts (to body): 25 Nm (18 ft lb)
Bolt (to engine): 50 Nm (37 ft lb)
- Transmission support:
Nuts (to transmission): 50 Nm (37 ft lb)
Bolt (to body): 50 Nm (37 ft lb)