Removing Transmission
Removing transmission, 012/01W, 5 SPD. M/T
^ First determine whether a coded radio is installed. In this case, determine the anti-theft coding.
^ Switch ignition off and disconnect battery Ground (GND) strap.
^ Unscrew expansion tank for cooling system and set it aside.
^ Remove intake manifold cover.
^ Remove Mass Air Flow (MAF) intake air hose.
^ Remove intake air scoop, if installed - arrows - and set aside.
^ Remove upper connecting bolts for engine/transmission. - Remove front wheels.
^ Remove covers from wheel housing - arrows -.
^ Remove noise insulation pan on bottom of engine/transmission, if installed.
^ Remove bracket for noise insulation pan, if installed - arrow -.
^ Removing front exhaust system with catalytic converter.
^ Remove cover plate over right drive axle - arrow 1 - and - arrow 2 -.
^ Remove cover plate over left drive axle, if installed.
^ Remove drive axles from flanged shafts and tie up as far away as possible so that protective coating is not damaged.
^ Remove shift mechanism from transmission as follows:
^ Remove shift rod - arrow A -.
^ Remove pivot rod, unscrew hex socket bolt, to do so - arrow B -.
^ Disconnect connector for Speedometer Vehicle Speed Sensor (VSS) - arrow A -.
^ Disconnect connector for back-up lights - arrow B -. Disconnect all other electrical connections and ground wires from transmission and from engine/transmission mounting bolts.
Vehicles with 5-cylinder engine
^ Attach Engine support bridge 10 - 222 A in conjunction with bracket for engine 10 - 222 A/1.
^ Mark installed position of engine mount from below - item 1 - and - item 2 -.
^ Unbolt nuts on both engine mounts.
^ Unbolt torque support from engine - arrows - and remove.
^ Unscrew right drive mount screws - 1 -.
^ Unscrew left drive mount nut - 2 - from subframe.
^ Lift up engine/transmission assembly via spindle of engine support bridge 10 - 222 A until engine fan contacts lock carrier beneath.
^ Unscrew engine/transmission connecting bolts at engine side - arrow A - and - arrow B -.
^ Bolt - arrow C - must not be removed yet.
^ Lower engine/transmission assembly via spindle to installed position again.
^ Tighten torque support, engine mount and left drive mount hand4ight.
Vehicles with 4-cylinder engine and 6-cylinder engine
^Remove bottom engine/transmission connecting bolts, except bolts - arrow A - and - arrow B -
Continuation for all vehicles
^ Assembly transmission jack with Transmission Support 3282, Adjustment Plate 3282/10 for "0127'01A" transmissions, and attachments as follows:
^ Set Adjustment Plate 3282/10 on to Transmission Support 3282 (adjustment plate only fits in one position).
^ Align transmission support arms to correspond with the holes in adjustment plate.
^ Screw in attachments - A -, as depicted on adjustment plate.
^ Set transmission jack under the vehicle, arrow - B - (fig. V 34-2583) on adjustment plate points in direction of travel/vehicle.
^ Align adjustment plate parallel to transmission and lock safety support - arrow - on transmission.
^ Remove right transmission support with bonded rubber bushing from transmission - arrows A -.
^ Remove left transmission support from bonded rubber bushing - arrow B -.
^ Remove engine/transmission connecting bolts - arrow A - and - arrow B -, if necessary, remove starter
^ Starter cables do not have to be disconnected.
^ For vehicles with 5-cylinder engine, bolt in lower starter area must now be removed.
^ Press transmission from alignment bushings and lower far enough until clutch slave cylinder is accessible.
^ Remove clutch slave cylinder - arrow - and secure with wire, do not disconnect line.
^ If installed, remove engine speed (RPM) sensor from coupling housing - arrow
^ Carefully lower transmission.
^ Change position of transmission in area of driveshafts when lowering via transmission jack spindles.
Secure transmission to assembly stand using Transmission Support VW 353 and Holding Plate VW 309 when performing repair work.