Removal And Installation: Transmission: Removing

WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. However, it is still accessible from the selected car via links, so may be relevant.

-- First, check whether a coded radio is installed. If so, obtain the anti-theft code.

-- Turn off the ignition and disconnect the battery ground cable. Refer to Removal and Installation .

-- If the lifting eye on the engine, that the engine support bridge 10-222 A will be connected to is covered by the engine cover with air filter, remove it. Refer to ENGINE COVER WITH AIR FILTER .

-- Remove the shift cable lock washer -arrow 1- from the selector lever -A-.

-- Remove the shift cable from the pin.

Fig 1: Removing/Installing Metal Relay Lever

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With a Metal Relay Lever

-- Remove the selector cable lock washer -2- from the relay lever -B-.

-- Remove the selector cable from the pin.

-- Remove the lock washer -arrow 3- from the relay lever -B- and then remove the relay lever.

With a Plastic Relay Lever

-- Remove the relay lever with the cable retainer. Refer to PLASTIC RELAY LEVER .

Continuation for all

-- Remove the nut -arrow 4- and then remove the transmission shift lever -A-.

-- Remove the cable bracket bolts -arrows- and bracket from the transmission.

Fig 2: Removing/Installing Cable Mounting Bracket At Transmission

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-- Tie up the shift and selector cables.

-- Remove the bracket -B- from the transmission and then pull it off the hose/line assembly -A-.

-- Remove the transmission support bolts -arrows A- and support.

Fig 3: Identifying Transmission Support And Slave Cylinder

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-- Remove the slave cylinder bolts -arrow B- and cylinder and lay it aside, secure with wire, do not open the hydraulic system.

CAUTION:

Do not press the clutch pedal anymore.

-- Disconnect the ground cable from the upper engine/transmission bolt.

-- Disconnect the connector -arrow 1- from the backup lamp switch -F4-.

Fig 4: Identifying Back-Up Light Switch And Starter Connectors

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-- Disconnect the connector -arrow 2- and wire -arrow 3- from the starter.

-- Remove the upper bolt from the starter.

-- Remove the upper engine/transmission bolts.

-- Disconnect any hoses and wires in the area of the lifting eyes on the engine.

-- Install the engine support bridge 10-222 A with the engine support feet 10-222 A /8, the engine support adapter 10-222 A/3 and the adapter 10-222 A/16 in front of the support.

Fig 5: Positioning Engine Support Bridge 10 - 222 A With Engine Support Feet 10 - 222 A/8, Adapter 10 - 222 A/3 And Adapter 10 - 222 A/16 In Front Of Hood Gas Shocks

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-- Attach the bracket with spindle and hook 10-222 A/10 to the engine at the front right side.

Fig 6: Installing Shackle 10-222 A/12 At Rear Left Of Engine

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-- Install the shackle 10-222 A/12 to the engine on the left rear side -arrow-.

-- Install the additional hook 10-222 A/2 to the shackle 10-222 A/12.

-- Then, attach the additional hook 10-222 A/2 to the adapter 10-222 A/16.

The left rear lifting eye on the engine faces upward -arrow- :

Fig 7: Hook 10-222 A/12 Adapter 10-222 A /16

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-- Engage the additional hook 10-222 A/2.

-- Then, attach the additional hook 10-222 A/2 to the adapter 10-222 A /16.

Continuation for all

-- Tension the engine/transmission assembly slightly using the spindles.

-- Lift the vehicle.

-- Remove the noise insulation. Refer to Description and Operation .

-- Remove the lower part of the left front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER .

-- Disconnect all wires from the transmission.

-- Remove the right drive axle heat shield bolts -arrows- and shield, if equipped.

Fig 8: Drive Axle Heat Shield Bolts

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-- Separate the exhaust system at the double clamp and remove the exhaust pipe suspended mount from the subframe. Refer to Description and Operation .

-- Remove the drive axles from the flange shafts and tie them up as high as possible. Be careful not to damage the surface protection.

-- Remove the pendulum support bolts -arrows A, B and C-.

Fig 9: Installing Pendulum Supports With New Bolts

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-- Remove the transmission mount to transmission mount bracket bolts -arrows-.

Fig 10: Identifying Left Subframe Mount

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-- Bring the engine/transmission assembly into an angled position by lowering it using the engine support bridge 10-222 A spindles.

Fig 11: Bringing Engine/Transmission Assembly Into Angled Position By Lowering It Over Engine Support Bridge 10 - 222 A Spindles

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NOTE:

Lower the threaded spindle on the adapter 10-222 A/16 using the wing nut until the threads are flush -arrow-.

Pay attention to the wires when lowering the transmission.

The bolts -arrows- for the transmission mount bracket -A- must be accessible.

-- Remove the transmission mount bracket -A- to transmission bolts -arrows-.

Fig 12: Identifying Transmission Plate Bolts

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-- Remove the small cover plate -A- for the flywheel (if equipped) behind the right flange shaft -arrow-.

Fig 13: Flywheel Small Cover Plate Behind Right-Hand Flanged Shaft

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-- Remove the exhaust system brace -1- from the transmission -arrow-.

Fig 14: Identifying Exhaust System Brace

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-- Remove the starter. Refer to STARTER [FOR ENGINE(S): BGP, BGQ, CBTA, CBUA] .

To remove the transmission, the adjustment plate 3282/39 must be installed on the transmission support 3282.

-- Install the transmission support 3282 onto the engine-/gearbox jack V.A.G 1383 A.

-- Align the arms of the transmission support so that they match up with the holes in the adjustment plate.

-- Install the mounting elements -A and C-, on the adjustment plate, as illustrated.

Fig 15: Identifying Transmission Support Adjustment Plate

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-- Position the engine-/gearbox jack under the vehicle. The arrow symbol -B- on the adjustment plate points in the direction of travel.

-- Align the adjustment plate so that it is parallel to the transmission and secure the safety support to the transmission.

Fig 16: Aligning Adjustment Plate Parallel To Transmission And Lock Safety Supports On Transmission

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-- Install the pin 3282/29 into the hole on the transmission for the pendulum support bolt.

-- Remove the lower engine/transmission bolts.

-- Disconnect the exhaust system if it is not possible to remove the lower bolts -arrows-.

Fig 17: Identifying Transmission Support Pin 3282/59

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-- Remove the transmission from the alignment sleeves and carefully move it toward the subframe.

Fig 18: Inclining Transmission With Spindles Of Transmission Support 3282

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-- Rotate the transmission downward in the area of the differential.

-- Push the engine forward slightly with help from a 2nd technician.

-- Carefully lower the transmission while guiding the right flange shaft -A- into the flywheel/intermediate plate area as shown.

Fig 19: Guiding Right Flange Shaft In Area Of Flywheel/Intermediate Plate

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-- Use the spindles on the transmission support 3282 to adjust the position of the transmission while lowering it.

NOTE:

Pay attention to the lines when lowering the transmission.