Removing and Installing
Transmission, removing and installing transmission on vehicles with 4- or 6 cylinder engine
Special tools and equipment
^ 3282 Transmission support
^ 3282/12 Adjustment plate
^ VAG 1331 Torque wrench
^ VAG 1332 Torque wrench
^ VAG 1383A Engine/transmission jack
^ T40013 Transportation device
Additional information
^ Refer to Steering and Suspension
^ Refer to Engine System
Removing
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Remove cover from engine.
Vehicles with 6-cyl. Diesel engine
- Remove heat shield from over turbocharger (arrows).
- Remove exhaust pipe securing nuts (arrows) at turbocharger manifold.
Continuation for all vehicles
- Remove sound insulation tray (arrows).
- Remove sound insulation tray bracket.
Vehicles with 6-cyl. Diesel engine
- Remove (arrows) exhaust system bracket -1-.
- Disconnect exhaust system at double clamp -2-.
- Remove front exhaust system with catalyst:
Vehicles with 4-cylinder engine
- Remove intermediate pipe of exhaust system:
Continuation for all vehicles
- Remove covers from wheel housings, if present (arrows).
- Remove protective plates for left and right axle shafts (arrows). Third bolt cannot be seen in illustration.
- Disconnect left and right axle shafts -1- from flanges and tie-up.
- Remove cover plate (arrows).
- Disconnect driveshaft from transmission.
- Push driveshaft back onto limit stop.
- Press driveshaft up onto heat shield with a wooden wedge (arrow).
- Remove Engine speed (RPM) sensor -G28- (if equipped) from top left of transmission housing (arrow).
- Disconnect speedometer sender connector.
- Disconnect back-up light connector.
- Unclip wires for speedometer and back-up light from transmission.
- Unbolt starter and set to one side in engine compartment.
Note: It is not necessary to disconnect the starter cable.
- Remove lower engine/transmission securing bolts.
- Mount transmission support 3282, adjustment plate 3282/12 for "01E" transmission and support elements as follows to transmission jack:
- Place adjustment plate 3282/12 on transmission support 3282 (adjustment plate fits only 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- (Fig.) on adjustment plate pointing to front of vehicle.
- Align adjustment plate parallel to transmission and lock safety support (arrow) on transmission.
- Remove bolts -1- and -2- to disconnect left and right transmission supports (complete with transmission mounting) from transmission and subframe.
- Using transmission jack VAG 1383A, lower transmission slightly.
Remove selector mechanism from transmission as follows:
- Unbolt connecting rod -2- for selector rod from right side of transmission.
- Remove push rod -1- by unbolting hex socket head bolt.
- Remove nut -1- and pull gear selector -2- from selector shaft of transmission.
- Remove clutch slave cylinder (arrow) and secure with wire without opening clutch hydraulic system.
Note: Do not depress clutch pedal.
- Remove upper engine/transmission securing bolts (arrows).
Vehicles with 6-cyl. Diesel engine
- Loosen bolt -1- (back of turbocharger) several turns and twist strut -2 aside in direction of arrow.
- Lightly tighten bolt -1-.
Continuation for all vehicles
- If bracket -3- is installed, set it aside with lines and secure with wire.
- Press transmission off dowel sleeves.
- Lower transmission carefully, ensuring clearance at axle shafts.
When work is performed on the transmission, it must be secured to the engine/transmission support VW 540.
Transporting the transmission
- Mount transportation tool T40013 to transmission lifting eye and secure.
- Secure workshop crane hook at 4th attachment point (arrow) on transportation tool.
- Lift transmission with workshop crane and transportation tool T40013.
Installing
- Clean input shaft splines and lightly grease with GOOD 100 grease.
- The clutch plate must be able to slide lightly back and forth on the input shaft.
- Check clutch release bearing for wear and replace if necessary.
- If plastic ring of release bearing is loose, glue it back on to release bearing with adhesive AMV 195 KD1 01.
- Three rectangular tabs (arrows) on plastic ring engage in notches of release bearing.
- If grooves are deeper than 0.5 mm, release bearing must be replaced.
- Check whether dowel sleeves for aligning engine/transmission are installed in cylinder block, install if necessary.
- Ensure that intermediate plate is correctly positioned on engine (if equipped).
- Thinly coat clutch release lever surface contacting plunger with copper grease.
- Before assembly, without exception, use a thread cutter to clean locking fluid residue from transmission flanged shaft threaded holes for driveshaft.
- Mount transmission support 3282, adjustment plate 3282/12 for "01E" transmissions and support elements as follows to transmission jack:
- Place adjustment plate 3282/12 on transmission support 3282 (adjustment plate fits only 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 with arrow symbol.
- Before installing transmission to a 6-cyl. Diesel engine, ensure that brace -2- is swung to side (direction of arrow).
- Install transmission, ensuring clearance at axle shafts.
- If bracket -3- is installed, push it along with any lines onto engine/transmission securing bolt.
Vehicles with 6-cyl. Diesel engine
- Loosen bolt -1- (toward back, on turbocharger) a few turns and swivel strut -2- down to vertical.
- Hand tighten engine/transmission securing bolts (arrows).
- Tighten bolt -1- to prescribed torque.
Continuation for all vehicles
- Tighten upper engine/transmission securing bolts to prescribed torque.
- Install slave cylinder with bracket for line/hose assembly and tighten bolt (arrow) to prescribed torque.
- Press gear selector -2- onto transmission selector shaft.
- Tighten nut.
- Bolt push rod -1- together with washers (if part of original equipment) to transmission.
- Bolt connecting rod -2- for selector rod to right side of transmission.
- Raise transmission with transmission jack VAG 1383A until transmission supports can be inserted.
- Bolt right and left transmission supports complete with transmission mounting to transmission and subframe (bolts).
- Install lower engine/transmission securing bolts and bolts for starter. When doing this install starter.
- Connect back-up light connector.
- Connect speedometer sender connector.
- Install Engine speed (RPM) sensor-G28-, if previously installed, on transmission housing (arrow).
- Connect driveshaft.
- Install protective plate (arrows).
- Mount axle shafts -1- to flange shafts.
- Install protective plates for left and right axle shafts (arrows). Third bolt cannot be seen in illustration.
- Install covers in wheel housings.
- Install front exhaust system with catalyst.
- Check transmission oil.
- Install sound insulation tray (arrows).
- Install engine cover.
- Reconnect Ground strap to battery.
- Enter radio code.
- Initialize power windows, set clock.
- Adjust selector mechanism.