Removing gearbox, as of 08.2010► — AUDI

🧭 Before you start

Fits: VW Caddy III (2K, 2004–2015); platform code 2C0

Don't miss

• There is no need to remove slave cylinder with securing bolts (arrows B).
• Do not depress clutch pedal.
• Be careful of all lines when lowering gearbox.

📋 Procedure

1. With ignition switched off, disconnect battery earth strap. Electrical system27Battery; Disconnecting and connecting battery
2. Remove engine cover panel from engine.
3. Remove complete air filter housing. 23Removing and installing air filter
4. Remove battery, battery cover and battery tray Electrical system27Battery; Removing and installing battery.
5. Remove securing clip (arrow 1) for gear selector cable from gearbox selector lever (A).

6. Remove securing clip (arrow 2) for gate selector cable from relay lever (B).
7. Pull gear selector cable and gate selector cable off pins.
8. Pull securing clip (arrow 3) off relay lever (B) and remove relay lever.
9. Remove gearbox selector lever (A) by removing nut (arrow 4).
10. Remove cable support bracket from gearbox (arrows).
11. Then use cable tie to tie up gear selector cable and gate selector cable.
12. Remove retainer (B) from gearbox and pull off from pipe/hose assembly (A).
13. Then remove gearbox support (arrow A). [Note: There is no need to remove slave cylinder with securing bolts (arrows B).]
14. Pull clip (A) for pipe/hose assembly out of slave cylinder to stop.
15. Pull pipe/hose assembly out of retainer (C) on gearbox.
16. Pull pipe/hose assembly (B) out of slave cylinder and seal opening. [Note: Do not depress clutch pedal.]
17. Remove earth strap at upper engine/gearbox connecting bolt.
18. Pull off reversing light connector (arrow 1).
19. Now remove connector (arrow 2) and wire (arrow 3) from starter.
20. Then remove upper securing bolt on starter.
21. Remove upper engine/gearbox connecting bolts.
22. Remove filler pieces from upper edge of left and right wings.
23. If there are hose and cable connections in area of engine support eye for support bracket10-222A, remove these now.
24. Set up support bracket10-222A together with adapters10-222A/30, adapter10-222A/3 and adapter10-222A/16 before gas strut for bonnet.
25. Attach hook10-222A/10 at front right of engine.
26. Now attach additional hook10-222A/2 to rear left of engine (arrow).
27. Connect hook10-222A/2 using adapter10-222A/16.
28. Take up weight of engine/gearbox assembly on spindles.
29. Raise vehicle.
30. Remove any noise insulation General body repairs, exterior66Noise insulation.
31. Remove front left wheel housing liner General body repairs, exterior66Removing and installing wheel housing liner; Front wheel housing liner.
32. Then remove all lines from gearbox.
33. Remove drive shaft shield from engine (arrows), if fitted.
34. Separate exhaust system at double clamp, and unbolt exhaust pipe bracket from subframe (arrows)26Emission control.
35. Disconnect drive shafts from flange shafts and tie up as high as possible, being careful not to damage surface protection.
36. Remove pendulum support (arrows A), (B) and (C).
37. Remove right-hand engine mounting from engine (arrows). 10Assembly mountings
38. Remove hexagon bolts (arrows) for left assembly mounting from gearbox mounting.
39. Tilt engine/gearbox assembly by lowering it via spindles of support bracket10-222A. [Note: Be careful of all lines when lowering gearbox.Lower threaded spindle of adapter10-222A/16 using winged nut, but not more than until spindle is flush with nut (arrow).When lowering gearbox assembly, observer coolant hose between engine and heat exchanger, being careful not to stretch it.Be careful of all lines when lowering gearbox.]
40. Remove gearbox bracket (A)(arrows).
41. If small cover plate (A) for flywheel behind the right flange shaft (arrows) is installed, remove it.
42. Remove exhaust system strut (1) from gearbox (arrow).
43. Remove starter. Electrical system27Starter
44. Insert gearbox support3282 in engine and gearbox jackV.A.G 1383A.
45. Align arms of gearbox support according to holes in adjustment plate.
46. Screw in support elements(A) and (C) on adjustment plate as shown.
47. Position engine and gearbox jack under vehicle. Arrow (B) on adjustment plate points in direction of vehicle travel.
48. Align adjustment plate parallel to gearbox and lock safety support on gearbox.
49. Then screw pin3282/39 into hole on gearbox for securing bolt of pendulum support.
50. Remove lower engine/gearbox connecting bolts.
51. Press gearbox off dowel sleeves and carefully swing towards subframe.
52. Have a second mechanic push engine forwards slightly.
53. Lower gearbox carefully. While doing this, guide right flange shaft (A) past intermediate plate and flywheel as shown.
54. Tilt gearbox in area of differential downwards in direction of subframe.
55. When lowering gearbox, change position of gearbox using spindles of gearbox support3282. [Note: Be careful of all lines when lowering gearbox.]

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