Removing and Installing
Transmission, removing and installing
Special tools, testers, materials required
^ Transmission jack VAG1383 A or equivalent
^ Transmission support 3282
^ Adjustment plate 3282/10
^ Lifting beam 3336
^ Grease G 000100
Removing
CAUTION:
^ Before disconnecting the battery, determine the correct coding for the anti-theft radio.
- Switch ignition off and disconnect battery ground strap.
- Remove coolant system expansion reservoir and set aside.
- Remove intake air hose.
- Remove upper engine/transmission securing bolts.
- Remove right-hand wheel.
- Remove undertray below engine/transmission.
- Remove undertray bracket (arrow).
- Remove front exhaust system with catalytic converter. Refer to Exhaust System.
- Remove cover plate over right-hand axle shaft flange (arrows 1 and 2).
- Remove cover above left-hand axle shaft.
- Disconnect axle shafts from transmission flanges and carefully tie shafts up as high as possible.
- Remove starter from engine/transmission and secure.
Note: It is not necessary to disconnect the starter cable.
Remove selector mechanism from transmission as follows:
- Remove selector rod (arrow-A-).
- Remove push rod by removing socket head bolt (arrow-B-).
- Remove connector from transmission vehicle speed sensor (arrow -A-).
- Remove connector for back-up lights (arrow -B-).
- Disconnect all other electrical connections and ground wires from transmission and from engine/transmission securing bolts.
- Remove lower engine/transmission securing bolts except for bolts (arrows -A- and -B-).
- Install transmission support 3282, adjustment plate 3282/10 for "012" & "01A" transmissions and support as follows to transmission jack:
- Place adjustment plate 3282/10 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 illustrated on adjustment plate.
- Place transmission jack under vehicle. Arrow (symbol -B- in illustration above) on adjustment plate points to front of vehicle.
- Align adjustment plate parallel to transmission and lock safety support (arrow) on transmission.
- Remove right transmission support with bonded rubber mounting from transmission (arrows -A-).
- Remove fastener from left transmission support to bonded rubber mounting (arrow -B-).
- Remove lower engine/transmission securing bolts (arrows -A- and -B-).
- Press transmission off dowel sleeves and lower until clutch slave cylinder is accessible.
- Remove clutch slave cylinder (arrow) and secure with wire. Do not disconnect hydraulic line from clutch slave cylinder.
- Lower transmission carefully.
- While lowering change position of transmission via transmission jack spindle, e.g. when in area of axle shafts.
Note: When working on the transmission, secure it to the repair stand with transmission support VW 353 and the retaining plate VW 309.
Transporting the transmission
When transporting the transmission and when setting up the transmission support 3282, the transmission lifting beam 3336 must be used.
- Bolt transmission lifting beam 3336 to clutch housing.
- Set support beam on sliding piece with locking pin (arrow).
No. of holes visible = 17
- Lift transmission with engine hoist and transmission lifting beam 3336.
Installing
- Clean input shaft splines and lightly grease with G 000 100 grease.
Note: The clutch plate must be able to slide lightly back and forth on the input shaft.
- Check clutch release bearing for wear, replace if necessary.
- Check whether dowel sleeves for aligning engine/transmission are installed in cylinder block and install if necessary.
- Check that intermediate plate is correctly positioned on engine.
- Assemble transmission jack with transmission support 3282, adjustment plate 3282/10 and support elements as follows:
- Place adjustment plate 3282/10 on transmission support 3282. (Adjustment plate only fits in one position).
- Align arms of transmission support according to holes in adjustment plate.
- Bolt support elements -A- onto adjustment plate.
- Place transmission on transmission jack.
- Align adjustment plate and transmission parallel with one another.
- Lock safety support (arrow) on transmission.
- Place transmission jack under vehicle, arrow symbol -B- on adjustment plate points to front of vehicle.
- Lift transmission until clutch slave cylinder with bracket for line/hose can be installed (arrow).
- Install intermediate plate between transmission and engine onto engine dowel sleeves.
- Install transmission.
- Install lower engine/transmission securing bolts and bolts for starter.
- Mount right transmission support with bonded rubber mounting to transmission and sub-frame (arrows -A-).
- Bolt left transmission support to bonded rubber mounting (arrow -B-)
Note: Install engine/transmission mountings stress-free.
- Mount axle shafts to transmission flanges.
- Install cover plate above right axle shaft flange (arrows 1 and 2).
- Install cover plate above left axle shaft.
- Push selector rod on so that securing bolts fits into recess in selector shaft.
- Tighten selector rod (arrow-A-).
- Tighten push rod to transmission (arrow -B-).
- Install front exhaust system with catalytic converter.
- Install undertray below engine/transmission.
- Install upper engine/transmission securing bolts.
- Connect back-up light connector (arrow-A-).
- Connect transmission vehicle speed sensor connector (arrow -B-).
- Install coolant system expansion tank.
- Install air intake hose.
- Reconnect ground strap to battery.
- If necessary, recode radio
- Check transmission oil.
- Adjust selector mechanism.
Tightening torques
Transmission to engine
Vehicles with 4-Cyl. engine
Vehicles with 6-Cyl. engine
Item A = Dowel sleeves
Transmission mountings
Axle shaft to flange M8 45 Nm (33 ft. lbs.)
Axle shaft to flange M10 80 Nm (59 ft. lbs.)
Clutch slave cylinder to transmission (arrow) 25 Nm (18 ft. lbs.)
Cover plate over axle shafts to transmission 20 Nm (15 ft. lbs.)
Selector rod to transmission (arrow -A-) 20 Nm (15 ft. lbs.)
Push rod to transmission (arrow -B-) 40 Nm (30 ft. lbs.)