Contents: Removal ↓ Installation ↓
The gearbox can be removed without dismantling the engine. First of all, it is necessary to release the fastening of the three engine mounts. In this case, a crane or hoist is required to support the engine. Removing the gearbox is necessary when the clutch needs to be replaced, as well as when the gearbox itself needs to be replaced or repaired. Since it is in no case advisable to repair the gearbox using improvised means, only the removal of the unit is described here.
Removal
Disconnect the battery ground (-) cable.
Caution: This will erase the engine fault codes and the radio code from the memory device. The battery may only be disconnected with the ignition switched off, otherwise the injection system control unit will be damaged. Before disconnecting, you must also read the instructions in the section "Removal and installation radio", and also "Removal and installation the battery".
Disconnect the electrical connectors at the gearbox.
Turbocharged Diesel Engine: Remove the air hose from the turbocharger to the charge air cooler.
Remove the gear shift lever and guide lever, as well as the cable counter support at the gearbox, see below.
Vehicles with hydraulic clutch:
Remove the gear shift cable with the guide lever so that the slave cylinder can be removed, see below.
Unscrew the clutch slave cylinder and hang it on a wire from the body.
Note: The hydraulic drive remains connected, otherwise the air must be bled from the system after installation. Do not depress the clutch pedal when the slave cylinder is removed.
Vehicles with mechanical clutch drive: disconnect the clutch cable from the gearshift lever at the gearbox and from the support, see chapter "Clutch". Vehicles with mechanical speed indicator: unscrew the speed indicator drive shaft from the gearbox.
Vehicles with electronic speed indicator: Disconnect the plug from the speed sensor.
Remove the 4 upper engine and gearbox mounting bolts.
Raise the car, see section "Lifting a car".
Disconnect the front exhaust pipe from the exhaust manifold and support it on a wooden stand.
Remove the starter, see chapter "Electrical equipment system".
Unscrew the protective shield of the cardan shaft.
Unscrew the cardan shafts on the left and right of the gearbox and tie both shafts up high.
Install a suspension device, such as a VW 10-222A, and pre-tighten the engine with a lead screw. If there is no suspension device, place a suitable rod on the trestles and tighten the engine with a cable.
Unscrew 3 bolts "A" at the engine support on the right "B".
Unscrew bolt C on the gearbox support on the left "D".
Caution: The bolt is partly difficult to access. On vehicles with power steering, carefully push the hydraulic lines to the side. On vehicles with anti-lock braking system, if necessary, remove the coolant expansion tank, see chapter "Cooling system".
Unscrew nut "A" of the front engine support.
Remove the front console "B" from the engine mount.
If available, bundle the power steering hoses together and securely tie them to the front of the vehicle, such as the front engine mount.
Unscrew the shock absorber from the front axle beam, see chapter "Front axle".
Move the power unit as far to the right as possible, and lift the engine a little more using a cable.
Note: If there is not enough space, remove the radiator fan, see chapter "Cooling system".
Unscrew support "A" and console "B" from the gearbox. Press the power unit against the front wall of the body and pull out the mounting bolt "C" from the gearbox console.
Note: Since 4/93 the gearbox console is no longer installed. If the console is present, it must be installed again during assembly.
Unscrew and remove the small protective screen of the gearbox.
It is easy to lift the gearbox with a V.A.G 1383 lift. If you don't have one, lift the gearbox with a garage jack.
Caution: Place a wooden block between the gearbox and the jack.
Remove the engine/gearbox mounting bolts.
Press the gearbox away from the guide bushings and carefully remove it.
Press the clutch release lever against the gearbox housing and secure it with a mounting pin or M8x35 bolt (length 35 mm). After installing the gearbox, remove the bolt and close the hole with a plug.
Installation
Before installation, check the clutch, see chapter "Clutch".
Check the clutch release bearing for ease of movement.
Attention: Only wipe the bearing, do not wash it. If before removal the bearing made noise when disengaging the clutch, replace the bearing, see chapter "Clutch".
Clean the splined engagement of the drive shaft and lightly lubricate with anti-friction paste or spray with molybdenum-based anti-friction spray.
Check if the engine block has guide bushings for centering the gearbox, otherwise install the bushings.
Raise the gearbox and insert it into the clutch in a horizontal position. If, during installation, the gearbox drive shaft does not fit into the splines of the driven clutch disc, turn the drive shaft by hand by the flange for the cardan shaft until the splines match.
Assemble in the reverse order to that of removal. Tighten the engine/gearbox mounting bolts (M12) alternately to 80 Nm.
Install the shock absorber and tighten the mounting bolts to 30 Nm, see chapter "Front axle".
Install the starter, see chapter "Electrical equipment system".
Tighten the gearbox support mounting bolts on the rear left side, do not tighten too much.
Remove the engine support device and tighten the front engine mount by hand. 0 Install the clutch slave cylinder and tighten the mounting bolt to 25 Nm. In vehicles with a mechanical clutch drive, install the cable rod, see chapter "Clutch".
Install the cardan shafts, see chapter "Front axle".
Screw on the cardan shaft protective screen.
Tighten the clutch housing to a torque of 10 Nm.
(The original information is posted on the website: «www.VWmanual.ru»)
Install the exhaust system, see chapter "Exhaust system".
Connect the electrical wires to the gearbox.
Turbocharged diesel engine: Install the air hose from the turbocharger to the charge air cooler. To do this, push the hose onto the connecting pipes and secure with clamps with a tightening screw, 0 Screw the gearshift drive to the gearbox.
Note: If the cable rods on the levers have been released, adjust the gear shift drive, see below.
Vehicles with mechanical speed indicator: screw the speed indicator drive shaft to the gearbox.
Vehicles with electronic speed indicator: connect the plug to the speed sensor.
Check the oil level in the gearbox, see below.
Align the power unit, tighten the supports to the specified torque value, see chapter "Engine".
Connect the battery ground (-) cable.
Caution: The battery may only be connected when the ignition is off, otherwise the injection system control unit will be damaged.
Adjust the clock.
Enter the anti-theft code for the radio, see section "Entering the radio code".
Perform a test drive.
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