Transmission, Removing
Transmission, Removing
Special tools, testers and auxiliary items required
• Hex bolt, M10 x 20
• Adapter (VW 771/40)
• Engine support bridge (10 - 222 A)
• Hook (10 - 222 A /10)
• Adapter (10 - 222 A /13)
• Engine/transmission jack (V.A.G 1383 A)
• Hose clamps up to 25 mm dia. (3094)
• Transmission support (3282)
• Adjustment plate (3282/33)
• Pin (3282/29)
• Transmission support jig (3336)
• Torque wrench (V.A.G 1331)
• Torque wrench (V.A.G 1332)
• Grease (G 000 450 02)
• Grease for clutch plate splines (G 000 100)
- Check whether a coded radio is installed. If this is the case obtain anti-theft coding.
- Disconnect battery ground (GND) cable with ignition switched off.
- Remove battery
- Remove lock washer - 3 - for shift cable from transmission shift lever - 1 -.
- Remove lock washer - 4 - for selector cable from actuator lever - 2 -.
- Pull off selector cable and shift cable from pin - arrows -.
- Remove cable mounting bracket bolts - arrows - from transmission.
- Then tie up shift cable and selector cable.
- Using hose clamps (3094) clamp off hose for hose/line assembly - A - to slave cylinder.
- Pull out clamp - arrow - for hose/line assembly up to stop.
- Pull hose/line assembly out of bleeder/slave cylinder.
CAUTION!
using Hose clamps (3094)
- Remove ground (GND) cable - 1 - from upper starter bolt.
- Disconnect connector for back up lights - 2 -.
- Disconnect connector and wiring from starter.
- Remove upper engine/transmission connecting bolts - 1 -.
- Remove upper bolt - 2 - on starter.
- Disconnect any hoses and cables in area of the engine support bridge (10 - 222 A), lifting eyes on engine.
- Attach engine support bridge (10 - 222 A) in conjunction with adapters (10 - 222 A /13) and hook (10 - 222 A /10) in front of gas-filled struts for hood.
- Engage bracket with spindle and hook (10-222A/10) into lifting eyelet on engine.
- Slightly pretension engine/transmission assembly on spindle.
- Raise vehicle.
- Remove sound insulation
- Remove front wheels.
- Remove front section of left front wheel housing liner
- If installed, remove left front level control system sensor (G78) - arrows -.
- Remove bracket from starter.
- Remove starter
- Disconnect connection - arrow - between connecting hose and charge air pipe.
- Remove exhaust system bracket from subframe - arrows -.
- Separate exhaust system at double clamp - arrows -.
- Tie up front exhaust pipe.
- If equipped, remove exhaust system support - 1 - from transmission - arrow - and front exhaust pipe.
- Remove pendulum support from transmission, bolts - 2 - and - 3 -.
- If installed, disconnect connector from oil level thermal sensor (G266).
- If installed, remove heat shield bolts - arrows - and shield for drive axle from engine.
- Remove left and right drive axles from flange shafts - A - of transmission.
- Secure drive axles with wire, making sure not to damage protective surface coating.
- Remove left and right coupling rods from stabilizer bar.
- Remove nuts - arrows - for ball joint at control arm on left and right sides.
- Remove steering gear from subframe and tie up.
- Secure subframe before removing.
- Remove subframe with pendulum support, stabilizer bar, brackets and control arms.
- Remove bolts - arrows - of left engine mount - 2 - from bracket - 1 -.
- By adjusting spindles, lower transmission by dimension - a - approximately 60 mm.
• When moving the engine/transmission assembly, be aware of the coolant hose between the engine and heater core; do not strain.
- Remove bracket - 1 - from transmission - arrows -.
- Pull off lock washer - arrow - from relay lever - 1 - and remove relay lever.
- Remove transmission selector lever from selector shaft.
- Remove small cover plate - A - for flywheel - arrows -.
- Remove lower engine/transmission bolts - 4 -.
• Loosen the engine/transmission bolt - 3 - and leave it screwed in hand tight.
To remove transmission, the transmission support (3282) is equipped with adjustment plate (3282/33).
- Insert transmission support (3282) in engine/transmission jack (V.A.G 1383 A).
- Align transmission support arms to correspond with holes in adjustment plate.
- Screw attachments - A -, as shown on adjustment plate.
- Screw in pin (3282/29) in place of attachment - C -
- Place engine/transmission jack (V.A.G 1383 A) under vehicle, with arrow symbol - B - on adjustment plate pointing to front of vehicle.
- Align adjustment plate parallel to transmission.
- Secure adapter (VW 771/40) in threaded hole of transmission housing as shown in the illustration.
- Screw stud (3282/29) into hole for mounting bolt of pendulum support on transmission.
- Secure transmission on transmission support (3282) using bolt (M10 x 20) - A -.
Drift - B - should sit flush at bottom with guide of transmission support (3282) - arrow -.
- Remove connecting bolt for engine/transmission - arrow -.
- Remove last connecting bolt of engine/transmission (item - C -, Fig. N34-10359).
- Press transmission off engine (locating sleeves).
- Using spindles of transmission support (3282) screw up transmission in area of the differential.
Right flange shaft - 1 - must be guided over bolt-on eyelet of engine - 2 -.
- Tilt transmission toward left via spindles of transmission support (3282).
- Carefully lower transmission.
• When lowering the transmission, be aware of the electromechanical steering gear - 3 -.
• Pay attention to all lines when lowering transmission.