Transmission, Removing And Installing: Notes
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2005 Volkswagen Jetta, 2005 Volkswagen GTI, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, and 2003 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.
Special tools and equipment
- 10-222 A Support
- 10-222 A/1 Support
- 10-222 A/2 Special hook
- 10-222 A/3 Adapter
- 3094 Hose clamps
- 3282 Transmission support
Special tools and equipment
- 3282/27 Adjustment plate
- 3282/48 Pins (Qty. 2)
- 3282/52 Support
- 3300 A Engine support
- 3336 Transmission lifting beam
- VAG 1331 Torque wrench
- VAG 1332 Torque wrench
- VAG 1383 A Engine/transmission jack
Special tools and equipment
- VAS 5024 Assembly pliers
- T10036 Support rail
Removing
NOTE:
Check whether a coded radio is installed as during the forthcoming work sequences the battery ground strap must be disconnected. Obtain the radio code first, if necessary.
- Remove cover from engine.
- With ignition switched off disconnect battery ground strap.
- Remove battery and battery carrier.
Refer to BATTERY, REMOVING AND INSTALLING
- Remove intake hose -1- , connector -2- and hose -3- from Mass Air Flow sensor.
- Remove complete air cleaner housing by removing bolts -4- and -5-.
Refer to AIR CLEANER, DISASSEMBLING AND ASSEMBLING for AWW & AWP engines, or AIR CLEANER ASSEMBLY, DISASSEMBLING AND ASSEMBLING for BDF engines .
- Remove intake hose -1-.
- Remove cable support bracket from transmission (arrows).
- Pull lock washer (arrow -1-) from gate selector cable relay lever -A-.
- Remove gear selector cable -B- with transmission selector lever by removing nut (arrow -2-).
NOTE:
Use a puller such as Kukko 20-10, if necessary.
- Unfasten power steering line (arrow -3-).
- Pull connector off speedometer sensor (arrow).
Fig 9: Starter Wiring, Back-up Light Connector, Starter Cable Retainer & Starter Upper Securing Bolt
- Remove wiring (arrow -1-) from starter.
- Disconnect back-up light connector (arrow -2-).
- Remove cable retainer (arrow -3-) on starter.
- Remove upper securing bolt on starter.
Fig 10: Identifying Special Tool 3094 On Clutch Slave Cylinder Hose & Pulling Out Clamp And Line/Hose
- Clamp clutch slave cylinder hose with special tool 3094.
- Pull out clamp (arrow) and line/hose in direction of arrow.
NOTE:
Do not depress clutch pedal.
- Remove ground strap at engine/transmission upper securing bolt.
- Remove engine/transmission upper securing bolts.
- Remove hoses and cable connections in area of engine mounting eye for support 10-222A.
Vehicles with 4-Cyl. engines
Fig 12: Support Bar 10-222A Together With Legs 10-222 A/1, Special Hook 10-222 A/2 And Adapter 10-222 A/3 (4-Cyl. Engines)
- Install support bar 10-222A together with legs 10-222 A/1, special hook 10-222 A/2 and adapter 10-222 A/3.
Vehicles with 6-Cyl. engines
Fig 13: Support Bar 10-222A Together With Legs 10-222 A/1, Special Hook 10-222 A/2 And Adapter 10-222 A/3 (6-Cyl. Engines)
- Install support bar 10-222A together with legs 10-222 A/1, special hook 10-222 A/2 and adapter 10-222 A/3.
Continued for all vehicles
- Take weight of engine/transmission assembly on spindles.
- Turn wheels fully onto left lock.
- Raise vehicle
- Remove sound insulation tray (arrows).
- Remove left sound insulation (arrows).
Vehicles with Diesel and 1.8 ltr. Turbo engines
- Remove charge air line between charge air cooler and turbocharger.
Continued for all vehicles
- Remove right sound insulation.
- Disconnect axle shafts from flanged shafts and tie up as high as possible. When tying up shafts do not damage body surface protection.
- Separate exhaust system and if necessary remove from subframe.
Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS for AWW & AWP engines, or 26 - EXHAUST SYSTEM, EMISSION CONTROLS for BDF engines
- Remove pendulum support (arrows -A- and -B-).
- Remove power steering line from starter and transmission.
- Remove starter.
Refer to STARTER, REMOVING AND INSTALLING
- Unbolt engine side of assembly mounting from engine carrier from above (arrows).
- Remove left assembly mounting -2- hex bolts (arrows) from left mount -1-.
- Carefully tilt engine and transmission by lowering left side spindle approx. 60 mm on support bar 10-222 A.
- Remove left mount -1- from transmission (arrows).
- Pull off gate selector cable -A- with relay lever in direction of arrow.
- Tie up selector cable with transmission selector lever and gate selector cable with relay lever.
- Incline engine/transmission assembly further by lowering it via left spindle of support bar 10-222A.
- Bolt support rail T10036 to both pendulum support securing holes on subframe (bolts -A-).
- Install support 3300 A so that it is almost touching assembly mounting and secure (arrows).
- Press engine/transmission forward carefully.
NOTE:
Do not damage any of the connecting lines and hoses when moving engine/transmission assembly.
- Remove lower rear engine/transmission securing bolts (arrow -A-).
- Remove lower engine/transmission securing bolts.
Set up transmission support 3282 with adjustment plate 3282/27 to remove transmission 02M.
- 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- (Refer to Illustration Fig 22 ) on adjustment plate points to front of vehicle.
- Align adjustment plate parallel to transmission.
- Secure transmission to transmission support 3282 with bolt -A-.
- Remove engine/transmission connecting bolt (arrow).
- Press transmission off dowel sleeves and carefully swing toward subframe.
- Lower transmission slightly and incline to left via spindles of transmission support 3282.
- Lower transmission carefully, guiding right side flanged shaft in area of flywheel and left side flanged shaft in area of subframe.
- When lowering, change position of transmission using transmission support 3282 spindles.
NOTE:
Do not damage power steering line when lowering transmission.
Transporting the transmission
- Bolt transmission lifting device 3336 to clutch housing.
- Set support beam on sliding piece with locking pin (arrow).
No. of holes visible = 6
- Take transmission out with workshop crane and transmission lifting device 3336.
- Lower transmission.
Installing
- Clean input shaft splines and lightly grease with G 000 100 grease.
Clutch plate must be able to slide lightly back and forth on input shaft.
- Check whether dowel sleeves for aligning engine/transmission are installed in cylinder block and install if necessary.
- Make sure that intermediate plate is correctly positioned on engine.
- Bolt support rail T10036 to both pendulum support securing holes on subframe (arrows).
- Install support 3300 A so that it is almost touching assembly mounting and secure (arrows).
- Press engine forward carefully.
NOTE:
Do not damage power steering line.
Set up transmission support 3282 with adjustment plate 3282/27 to install transmission 02M.
- Align arms of transmission support according to holes in adjustment plate.
- Bolt support elements -A-, as illustrated, on adjustment plate.
- Place transmission on transmission jack.
- Align adjustment plate and transmission parallel with one another.
- Place transmission jack under vehicle. Arrow symbol -B- (See N34-1052) on adjustment plate points to front of vehicle.
- Secure transmission to transmission support 3282 with bolt -A-.
- Incline transmission to left via spindles of transmission mounting 3282.
- Install transmission.
NOTE:
Do not damage power steering line.
- Install lower rear engine/transmission connecting bolt (arrow -A-).
- Install lower engine/transmission securing bolts.
- Remove pressing device 3300 A (arrows).
- Remove bolts -A- and remove support rail T10036.
- Install gate selector cable -A- with relay lever in direction of arrow.
- Install left mount -1- on transmission (arrows).
- Align engine/transmission in installation position.
- Install new hex bolts (arrows) for left assembly mounting -2- in mount -1-.
- Install new hex bolts (arrows) for right assembly mounting in engine mounting.
WARNING:
Do not remove support bar 10-222A until the bolts securing the left and right assembly mountings have been tightened to torque setting.
- Use new bolts and install pendulum support (arrows -A- and -B-).
Refer to 40 FRONT SUSPENSION
- Install axle shafts to transmission.
Refer to 40 FRONT SUSPENSION
- Reconnect exhaust system.
Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS for AWW & AWP engines, or 26 - EXHAUST SYSTEM, EMISSION CONTROLS for BDF engines
- Install starter and secure with lower bolt.
- Install retainer for power steering line on starter and on transmission.
- Install upper engine/transmission securing bolts.
- Tighten upper engine/transmission securing bolts to prescribed torque. Refer to Tightening torques or Transmission, removing and installing
- Install ground strap at upper engine/transmission securing bolt.
- Attach connector to speedometer sensor (arrow).
- Push line/hose in direction of arrow and press down clamp (arrow).
- Remove special tool 3094.
- Install upper securing bolt on starter.
Fig 38: Starter Wiring, Back-up Light Connector, Starter Cable Retainer & Starter Upper Securing Bolt
- Install cable retainer -A- on starter (arrow -3-).
- Attach connectors for starter (arrow -1-) and back-up light (arrow -2-).
NOTE:
All repairs on the starter:
Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- Install cable support bracket on transmission (arrows) and tighten bolts to torque setting. Refer to Selector cables, assembly overview pos.Selector cables, assembly overview .
Fig 40: Gate Selector Cable Relay Lever, Lock Washer, Gear Selector Cable, Nut & Power Steering Line
- Install gear selector cable -B- with transmission selector lever (arrow -2-).
- Tighten hex nut (arrow -2-) to prescribed torque. Refer to Selector cables, assembly overview pos.Selector cables, assembly overview .
- Secure gate selector cable -A- with relay lever using lock washer (arrow -1-).
- Install power steering line (arrow -3-).
- Install battery carrier.
Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- Install complete air cleaner housing by tightening bolts -4- and -5-.
- Install intake hose -1-.
- Attach connector -2- and hose -3- to Mass Air Flow sensor.
- Install battery.
Refer to BATTERY, REMOVING AND INSTALLING .
NOTE:
Note radio coding for vehicles with coded radio.
- Check transmission oil. Refer to Transmission gear oil, checking .
- Specifications. Refer to Code letters, application, ratios, capacities .
- Bleed clutch system. Refer to Clutch system, bleeding .
- Adjust gear selector mechanism. Refer to Gear selector mechanism, adjusting .
- Install engine cover.
- Install insulation tray below engine/transmission, if so equipped.