Removing and Installing
Transmission, removing and installing
Special tools and workshop equipment required
- 3282 Transmission support
- 3282/10 Adjustment plate
- VAG 1331 Torque wrench
- VAG 1332 Torque wrench
- VAG 1383 A Engine/transmission jack
- 3336 Transmission lifting tackle
Additionally required for vehicles with 5-cylinder engine
- 10-222A Support bracket
Removing
- First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.
- With the ignition switched off disconnect the battery Ground (GND) strap.
- Remove coolant system expansion reservoir and lay to one side.
- Remove the intake manifold cover.
- Remove intake hose from air mass meter.
- Remove intake elbow (if fitted) and lay to one side.
- Remove upper engine/transmission securing bolts.
- Remove front wheels.
- Remove covers from wheel housing (arrows).
- Remove insulation tray below engine/transmission, if fitted.
- Remove insulation tray bracket, if fitted (arrow).
- Remove front exhaust system with catalyst.
- Remove cover plate over the right-hand drive shaft (arrows 1 and 2).
- If fitted, remove cover above left-hand drive shaft.
- Disconnect drive shafts from flanged shafts and tie up as high as possible, when doing this, do not damage surface protection.
Remove selector mechanism from transmission as follows:
- Remove selector rod (arrow -A-).
- Remove push rod, to do this remove hexagon socket head bolt (arrow -B-).
- Pull connector off road speed sender (arrow -A-).
- Pull off reversing light connector (arrow -B-). Disconnect all other electrical connections and Ground (GND) wires from transmission and from the engine/transmission securing bolts.
Vehicles with 5 and 6-Cyl. engines
- Fit support bar 10-222A together with supports 10-222 A/1.
- Mark installation position (items -1- and -2-) of both engine mountings from below.
- Remove nuts for both engine mountings (arrows).
- Remove torque rod support on engine (arrows) and take out
- Then remove right transmission support bolts -1-.
- Remove left transmission support nut -2 from sub-frame
- Lift engine/transmission assembly via the spindles of support bar 10-222A until the engine radiator fan lies against the underside of the bumper.
- Remove engine/transmission connecting bolts from engine side (arrows -A- and -B-).
- Do not remove bolt (arrow -C-) at present.
- Lower engine/transmission assembly back to installation position again using spindles.
- Tighten torque rod support, engine mounting and left transmission support again hand tight.
Vehicles with 4-Cyl. engine and 6-Cyl. engine
- With the exception of bolts (arrows -A- and -B-) remove lower engine/transmission securing bolts.
Continued for all vehicles
- Fit transmission support 3282, adjustment plate 3282/10 for "012" "01A" transmissions and support elements 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 -B- on adjustment plate points to front of vehicle.
- Align adjustment plate parallel to transmission and lock safety support (arrow) on transmission.
- Then remove right transmission support with bonded rubber mounting from transmission (arrows -A-).
- Detach the left transmission support from the bonded rubber mounting (arrow -B-).
- Remove engine/transmission connecting bolts (arrows -A- and -B-) remove starter motor when doing this if necessary.
- It is not necessary to disconnect the starter cable.
- Vehicles with 5-cylinder engine, the bolt in lower area of starter must be removed now.
- Press transmission off dowel sleeves and lower until the clutch slave cylinder is accessible.
- Remove clutch slave cylinder (arrow) and secure with wire, do not disconnect pipe.
- Then remove engine speed sender from clutch housing (if fitted) (arrow).
- Lower transmission carefully.
- When lowering the transmission change position of transmission via the transmission jack spindle when in the area of the drive shafts.
When working on the transmission, it must be secured to the repair stand with transmission support VW 353 and the retaining plate VW 309.
Transporting the transmission
When transporting the transmission and also when setting up transmission support 3282, the transmission lifting beam 3336 should 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 workshop crane and transmission lifting beam 3336.
Installing
- Clean input shaft splines and lightly grease with GOOD 100 grease.
The clutch plate must be able to slide lightly to and fro on the input shaft.
- Check clutch release bearing for wear, replace if necessary.
- Check whether dowel sleeves for aligning engine/transmission are fitted in cylinder block, install if necessary.
- Ensure that the intermediate plate is correctly positioned on engine (if fitted).
- Thinly coat clutch release lever surface contacting plunger.
- The threads of all threaded holes, in which self-locking bolts are screwed, should be cleaned of locking fluid remains using a thread cutter.
- Assemble transmission jack with transmission support 3282, adjustment plate 3282/10 for "012" "01A" transmission 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 on support elements -A-, as illustrated on 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 -B- on adjustment plate points to front of vehicle.
- Lift transmission until the clutch slave cylinder with the bracket for the pipe/hose can be installed (arrow).
- Then install engine speed sender-G28-, if previously fitted, on transmission housing (arrow).
- Fit intermediate plate (if fitted) onto engine dowel sleeves between transmission and engine.
- Ensure when inserting the transmission that the drive shaft flanges are located in the transmission flange shafts.
- Insert transmission.
- When installing, press engine up at torque rod support (in direction of arrow) if necessary (2nd mechanic).
- Install lower engine/transmission securing bolts and bolts for starter when doing this install starter.
Vehicles with 5 and 6-Cyl. engines
- Bolt right transmission support to transmission.
- Lift engine via the spindles of support bar 10222A until the radiator fan lies against the underside of the bumper.
- Install lower engine/transmission securing bolts (arrows -A-, -B- and -C-).
- Bolt left and right transmission support with bonded rubber mounting to sub-frame.
- Bolt torque rod support to engine
- Tighten new nuts for both engine mountings.
Note: Install engine/transmission mountings stress-free.
Vehicles with 4-Cyl. engine and 6-Cyl. engine
- Unbolt right transmission support with bonded rubber mounting to transmission and sub-frame (arrows -A-).
- Bolt left transmission support to bonded rubber mounting (arrow-Be) (illustrated in conjunction with 6-cyl.
engine).
Note: Install engine/transmission mountings stress-free.
Continued for all vehicles
- Fit drive shafts to flange shafts.
- Fit the cover plate above the right drive shaft (arrows 1 and 2).
- If fitted install the cover plate above the left drive shaft.
- Push selector rod on so that the securing bolt fits in the recess in the selector shaft.
- Then tighten the selector rod first (arrow -A-).
- Then tighten push rod to transmission (arrow -B-).
- Install front exhaust system with catalyst.
- Install insulation tray below engine/transmission, if fitted.
- Connect reversing light connector (arrow -B
- Connect speedometer sender connector (arrow -A-).
- Install upper engine/transmission securing bolts.
- Secure coolant system expansion tank.
- Fit intake hose to air mass meter.
- Then assemble air intake duct
- Install intake manifold cover.
- Reconnect Ground (GND) strap to battery.
Note: Note radio coding for vehicles with coded radio.
- Checking transmission oil.
- Adjusting selector mechanism - the shift lever must be pressed down to engage the reverse gear.
- Adjusting selector mechanism - the shift lever is not pressed down to engage the reverse gear.
Tightening torques
Transmission to engine
Vehicles with 4-cyl engine Bolt Locations
Vehicles with 4-cyl engine Tightening Torque
Vehicles with 5-cyl engine Bolt locations
Vehicles with 5-cyl engine Tightening Torque
Item A = Dowel sleeves (both illustrations)
Vehicle with 6-cyl engine Bolt locations
Vehicles with 6-cyl Tightening torque
Item A = Dowel sleeves
Assembly mountings
Vehicles with 4-Cyl. engine part 1 of 2
Vehicles with 4-Cyl. engine part 2 of 2
Vehicles with 4-Cyl. engine Mount Locations
Vehicles with 5-Cyl.
Vehicles with 5-Cyl. Mount locations
Vehicles with 6-Cyl.
Vehicles with 6-Cyl. Mount locations
Selector rod (selector joint) to transmission (arrow-A-) 23 Nm
Bolts and other components which have direct contact with the transmission casing have a surface which is matched to the transmission casing depending upon whether it is manufactured from aluminum or magnesium.