Modifying Support Rails VW 45711

Modifying support rails VW 45711, 02J, 5 Spd. M/T
Support rails VW 457/1 are required to remove and install the transmission.

To secure support rail VW 457/1 to the subframe a new hole is required.
Dimensions given are in mm.
- Drill an 8.5 mm diameter hole (arrow) in support rail VW 457/1.

Removing
- Remove cover from engine.

Note: Check whether a coded radio is installed as during the forthcoming work sequences the battery ground strap must be disconnected. Obtain radio code first if necessary.

- With ignition switched off disconnect battery ground strap.

- Remove intake hose -1-, connector -2- and hose -3- from mass air flow sensor.
- Remove complete air cleaner housing by unscrewing bolts -4- and -5-.

Transmissions up to 05.99

- Pull connector off vehicle speed sensor (arrow -1-)
- Disconnect reverse light connector (arrow -2-).

- Remove balance weight -A- and gear selector cable -B- from gear selector lever.
- Remove gear selector cable with washer and square nut (self-locking).
- Lift tab in direction of arrow and pull gate selector cable off actuating arm/relay lever -C-.

- Remove cable support bracket from transmission (arrows). If necessary unclip hose at cable support bracket first.

- Remove slave cylinder place to side and secure with wire, do not disconnect lines.

Note: Do not depress clutch pedal.

- Remove cable retainer (arrow -1-) on starter.
- Remove upper securing bolt (arrow -2-) on starter.
- Remove ground strap at engine/transmission upper securing bolt.
- Remove engine/transmission upper securing bolts.

Transmissions from 05.99

- Remove cable support bracket from transmission (arrows). If necessary unclip hose at cable support bracket first.

- Remove circlip and pull off gate selector cable -A- with relay lever.
- Remove nut (arrow) and remove gear selector cable -B with transmission selector lever.
- Tie selector cable with transmission selector lever and gate selector cable with relay lever up.

- Disconnect connector from vehicle speed sensor (arrow -1-).
- Disconnect reverse light connector (arrow -2-).

- Remove slave cylinder and place to side, secured with wire. Do not disconnect hydraulic lines.

Note: Do not depress clutch pedal.

- Remove cable retainer (arrow -1-) on starter.
- Remove wiring and cable from starter.
- Remove ground strap at engine/transmission upper securing bolt.
- Remove upper securing bolt (arrow -2-) on starter.
- Remove engine/transmission upper securing bolts.
- If there are hoses and cable connections in area of engine mounting eye for support 10-222A, remove these now.

Continued for vehicles with 4-Cyl. engine
- Fit support bar 10-222A together with legs 10-222 A/1.

Continued for vehicles with 6-Cyl. engines
- Fit support bar 10-222A together with legs 10-222 A/1 and adapters 10-222 A/3.

Continued for all vehicles
- Take weight of engine/transmission assembly on spindles.
- If fitted, remove center and left part of insulation tray below engine/transmission.
- Remove power steering line from starter and transmission.
- Remove starter.
- Remove right hand inner constant velocity joint protective cover from engine if fitted.
- Turn wheels fully onto left lock.
- Disconnect drive shafts from flanged shafts and tie up as high as possible. Do not damage surface protection of parts.

- Remove flywheel small cover plate -A- behind right-hand flanged shaft (arrows), if fitted.
- Remove lower flywheel cover plate, if part of original equipment.
- Separate exhaust system and if necessary remove from subframe.

- Remove pendulum support (arrows -A- and -B-).

- Remove transmission support (arrow -A-) from transmission.
- Remove hex bolts (arrows -B-) from left-hand hand assembly mounting.
- Incline engine/transmission assembly by lowering it via left spindle of support bar 10-222A.
^ The transmission mount -A- securing bolts (arrows) must be accessible.

- Remove transmission mount -A- (arrows).

- Bolt support rail VW 457/1 to both pendulum support securing holes on subframe.
- Insert spacers totaling 6 mm between subframe and support rail VW 457/1.
- -A- Qty. 2 hex bolts M8 x 25
- Fit support 3300 A and secure (arrows).

Vehicles with 5 valve engine
- Remove a lower engine/transmission securing bolt so that support 3300 A can be installed.

The support 3300 A must be installed directly next to the transmission on the engine.

Continued for all vehicles
- Press engine/transmission forward carefully.

Note: Do not damage power steering line when moving engine/transmission assembly.

- Assemble transmission jack with transmission support 3282, adjustment plate 3282/8 for 02A transmission and support elements as follows:
- Place adjustment plate 3282/8 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-, as illustrated, on adjustment plate.

- Place transmission jack under vehicle. Arrow symbol -B- go to Illustration V34-2670) on adjustment plate points to front of vehicle.
- Align adjustment plate parallel to transmission and lock safety supports on transmission.
- Remove lower engine/transmission securing bolts.

- Press transmission off dowels and carefully swing towards subframe.
- Lower transmission slightly and incline to left via spindles of transmission support 3282.

- Lower transmission carefully guiding right-hand flange shaft -A- in area of flywheel as illustrated. Guide left-hand flange shaft -B- in area of subframe.

Note:
^ When lowering, change position of transmission using the transmission support 3282 spindles.
^ Do not damage power steering line when lowering transmission.

Transporting the transmission

- Bolt transmission lifting device 3336 to clutch housing.

- Set support arm on sliding piece with locking pin (arrow).

No. of holes visible = 5

- Lift transmission with workshop crane and transmission lifting device 3336.
- Place transmission, for example, onto transport container.

Installing

Note:

^ Before installing the transmission press the clutch release lever toward the transmission housing and secure it with an assembly pin, assembly bolt or a M8 x 35 bolt. Remove it after the transmission has been installed. The hole will then be sealed by the 3rd cable support bracket securing bolt or plugged.

^ When replacing a transmission, the sensors for the speedometer (Fig.), gear selector and relay lever must be transferred to the new assembly.

- Clean input shaft splines and lightly grease with G000 100 grease.

The clutch plate must be able to slide lightly back and forth on the input shaft.

- Check whether dowel sleeves for aligning engine/transmission are fitted in cylinder block, install if necessary.
- Ensure that intermediate plate is correctly positioned on engine.

- Bolt support rail VW 457/1 to both pendulum support securing holes on subframe.
- Insert spacers totaling 6 mm between subframe and support rail VW 457/1.
- A- Qty. 2 hex bolts M8 x 25
- Fit support 3300 A and secure (arrows).

Vehicles with 5 valve engine
The support 3300 A must sit on the threaded boss on the engine.

Continued for all vehicles
- Press engine forward carefully.

Note: Do not damage power steering line.

- Assemble transmission jack with transmission support 3282, adjustment plate 3282/8 for 02A transmission and support elements as follows-.
- Place adjustment plate 3282/8 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 and lock safety supports on transmission.

- Place transmission jack under vehicle, arrow symbol -B- go to Illustration V34-2670) on adjustment plate points to front of vehicle.
- Incline transmission to left via spindles of transmission mounting 3282.
- Insert transmission.

Note: Do not damage power steering line.

- Install lower engine/transmission securing bolts.

- Remove support 3300 A (arrows).
- Remove bolts -A- and remove support rail VW 457/1.
- Install upper engine/transmission securing bolts.

- Install transmission mount -A- with new bolts (arrows).
- Align engine/transmission in installation position.

- Install new hex bolts (arrows -B-) for left hand assembly mounting in transmission mounting.
- Mount transmission support (arrows -A-) to transmission.

WARNING! Do not remove support bar 10-222A until the bolts securing the left-hand transmission mount have been tightened to torque setting.

- Install lower engine/transmission securing bolt (arrow -A-).
- Install pendulum support (arrows). Use new bolts for securing.
- Reconnect exhaust system.
- Install retainer for power steering line on starter and on transmission.

- If removed, install small cover plate -A- behind right-hand drive flange (arrows).
- If removed, install large cover plate for clutch.
- Fit drive shafts to transmission.
- If removed, install protective cap for right-hand inner constant velocity joint to engine.
- Install starter.

- Install slave cylinder.

- Install cable support bracket on transmission (arrows), if necessary push hose onto cable support bracket.

Transmissions up to 05.99

- Install gear selector cable -B- and balance weight -A- on gear selector lever.
- Lift tab in direction of arrow and fit gate selector cable on follower/relay lever -C-.

- Attach reverse light connector (arrow -2-). Attach all other electrical connections and ground wires to transmission and to engine/transmission securing bolts.
- Attach connector to speedometer sensor (arrow -1-)
- Assemble air intake duct.
- Reconnect ground strap to battery.

Note: Note radio coding for vehicles with coded radio.

- Check transmission oil.
- Adjust gear selector mechanism.
- Install engine cover.
- Install insulation tray below engine/transmission, if fitted.

Transmission from 05.99

- Fit gear selector cable -B- with transmission selector lever (arrow).
- Fit gate selector cable -A- with relay lever and secure (arrow).

Vehicles with 4-Cyl. engine

Items A + B - Fitting sleeves

Vehicles with 6-Cyl. engine

1) Also starter to transmission
2) Only on engines with an aluminum oil pan, on some engines M10 x 50 bolts are fitted and the tightening torque is 25 Nm.
3) Flywheel cover plate only on engines with a sheet steel oil pan (pan painted black)

Items A + B - Fitting sleeves

Transmission mount -A- to transmission 50 Nm + 90°

- Replace bolts (arrows).

Transmission to body

Rear transmission mounting

- Replace bolts

Note: Install engine/transmission mountings stress-free.