Removing and installing gearbox for vehicles with short front end — VW

Special tools, workshop equipment, test and measuring appliances and aux. items required

3184 Gearbox support
3184/1 Auxiliary support (to modify => Page
34-63
)
3227 Engine repair stand
3250 Support
3299 Ribbed belt lever
V.A.G 1383 A Engine/gearbox jack

Special tools, workshop equipment, test and measuring appliances and aux. items required

3257 Socket, 27 mm AF
3282 Gearbox support
3282/16 Adjustment plate
3336 Gearbox lifting beam
V.A.G 1331 Torque wrench
V.A.G 1332 Torque wrench

Additional information

Workshop Manual Transporter 1991 ▸, Running gear
Workshop Manual Transporter 1991 ▸, Running gear, axles, steering from January 1996
Workshop Manual Transporter 1991 ▸, Electrical system
Workshop Manual Transporter 1991 ▸, 5-Cyl. diesel engine, mechanics
Workshop Manual Transporter 1991 ▸, 5-Cyl. injection engine, mechanics

Modifying auxiliary support 3184/1

Create two 45 °chamfers on each arm so that the auxiliary support 3184/1 for support device 3184 can continue to be hooked into the cross panel.

Dimension -a- = 5 mm

Removing

For vehicles with coded radio obtain radio code.
Remove battery covering.
With the ignition switched off disconnect the battery earth strap (in engine compartment and if fitted, under driver's side).

=> Electrical system; Repair group 27; Battery; Removing and installing battery
Electrical system
Battery
Removing and installing battery

Remove bolts -1- and fold radiator out in direction of arrow.

Vehicles up to 12.95

Fit support device 3250 before lifting vehicle.

=> Running gear; Repair group 40; Servicing front suspension
Running gear
Servicing front suspension

If the supporting device cannot be inserted, even after loading, then the torsion bar tension can be relieved.

=> Running gear; Repair group 40; Servicing front suspension; Removing and installing torsion bar/Adjusting torsion bar
Running gear
Servicing front suspension
Removing and installing torsion bar/Adjusting torsion bar

Continued for all vehicles

With the vehicle resting on its wheels loosen left-hand wheel hub/drive shaft bolt and left and right-hand wheel securing bolts.
Lift vehicle until the load on the front axle is relieved.
Remove front wheels.
Remove hexagon bolt for drive shaft/wheel hub.
Raise vehicle.

Vehicles from 01.96

Support device 3250 can no longer be used.

The torsion bars are relieved when vehicle is raised.

Measure lengthof threadfrom nut to face of torsion bar threaded rod -a- and note value.

Relieve tension on torsion bar with special tool 3257.

=> Running gear, axles, steering from January 1996; Repair group 40; I - Removing and installing subframe, anti-roll bar, torsion bar, wishbone, shock absorber; Removing and installing torsion bar/Adjusting torsion bar
Running gear, axles, steering from January 1996
I - Removing and installing subframe, anti-roll bar, torsion bar, wishbone, shock absorber
Removing and installing torsion bar/Adjusting torsion bar

Continued for all vehicles

Remove noise insulation tray below engine/gearbox.

Remove left-hand drive shaft as follows:

Remove bolt for left-hand shock absorber/anti-roll bar coupling rod.
Push shock absorbers completely together.
Disconnect drive shaft at flange.

Separate left-hand lower wheel bearing housing swivel joint bolted connection, thereby support swivel joint, e.g. with gearbox jack V.A.G 1383 A so that it does not drop down quickly.
Take drive shaft out.
Disconnect right-hand drive shaft at flange.

Remove bolt for right-hand shock absorber/anti-roll bar coupling rod.
Push right-hand shock absorber completely together.
Raise right drive shaft and secure.
Remove earth strap from gearbox and mounting bracket.
Remove all electrical connections from gearbox and starter motor.

=> Electrical system; Repair group 27; Starter motor; Removing and installing starter motor
Electrical system
Starter motor
Removing and installing starter motor

Unscrew speedometer drive shaft cable or remove sender connector and speedometer sender.

If so attached detach electrical wiring from coolant hoses.
Detach coolant piping at starter motor (arrows) (from expansion tank to water pump).
Remove wiring loom from pipework.
Remove starter.

=> Electrical system; Repair group 27; Starter motor; Removing and installing starter motor
Electrical system
Starter motor
Removing and installing starter motor

Remove selector mechanism from gearbox as follows:

Remove swivel head (arrow 1).
Lever front selector rod off gearbox selector lever (arrow 2).
Unbolt mounting bracket with gate rod (arrow 3).
Tie-up selector and gate rods.

Vehicles with mechanical clutch control

Detach clutch cable at gearbox and at gearbox mounting bracket => Page
30-35
.

Vehicles with air conditioning system

Release tension in ribbed V-belt and take belt off alternator and compressor.

=> 5-Cyl. injection engine Mechanics; Repair group Gr. 13

=> 5-Cyl. diesel engine Mechanics; Repair group 13
5-Cyl. diesel engine Mechanics

Removing alternator.

=> Electrical system; Repair group 27
Electrical system

Remove compressor from mounting bracket and secure to body so that the hoses are stress free.

War
The air conditioning refrigerant circuit must not be opened. The refrigerant hoses are prone to kinking.
=> Heating, air conditioning system; Repair group Gr. 87

Note:

When removing gearbox or moving engine/gearbox assembly, there is a danger of damaging the air conditioner refrigerant circuit pressure switch.

Detach refrigerant hose (arrow 1) from front right-hand longitudinal member between air conditioning system sight glass/pressure switch and fluid container to do this remove bolt for clamp (arrow 2).

Vehicles with 5-Cyl. injection engine

Remove Lambda probe from front exhaust pipe if fitted.
Remove front exhaust stop plate.

=> 5-Cyl. injection engine, Mechanics; Repair group 26; Removing and installing parts of exhaust system.
5-Cyl. injection engine, Mechanics
Removing and installing parts of exhaust system.

Separate front exhaust pipe at catalyst.

=> 5-Cyl. injection engine, Mechanics; Repair group 26; Removing and installing parts of exhaust system.
5-Cyl. injection engine, Mechanics
Removing and installing parts of exhaust system.

Vehicles with 5-Cyl. diesel engine

Remove front exhaust pipe

=> 5-Cyl. Diesel engine, Mechanics; Repair group 26; Removing and installing parts of exhaust system
5-Cyl. Diesel engine, Mechanics
Removing and installing parts of exhaust system

Continued for all vehicles

Remove front propshaft =>Page
39-100
.
Remove bolts -3- and separate flexible joint/heat shield from bevel box output flange.

Bolt engine support to block.

Hook auxiliary support 3184/1 for support device 3184 in cross panel (arrow). If necessary, remove wiring harnesses and pipes from cross panel.

Fit support device 3184 into auxiliary support 3184/1 and into subframe -A-. Screw spindle -C- into hole on engine mounting.
Align support device so that the slide -B- is resting against the right-hand tube (arrow).
Secure support device to subframe -A- and to auxiliary support 3184/1 by tightening the angle plates.
Relief subframe loading by raising engine/gearbox by means of spindle -C-.

Vehicles up to 12.95

Remove bolt (arrow 1) of rear assembly carrier (arrow 2).

Vehicles from 01.96

Remove pendulum support, to do this remove bolts -A- and -B-.

Vehicles up to 12.95

Unscrew bearing bracket -A- from bonded rubber mounting at body (arrow 1).
Lower engine using support device spindle.
Unscrew bearing block -A- from gearbox (arrow 2).

Vehicles from 01.96

Unbolt gearbox mounting from body (arrow 1).
Lower engine using support device spindle.
Unscrew mounting bracket from gearbox (arrows 2).

Vehicles with hydraulic clutch control

Remove slave cylinder (arrows) and place to side, secure with wire, do not open system.

Note:

Do not depress clutch pedal.

Continued for all vehicles

Carefully swing engine/gearbox forward alternately and lower until the V-belt pulley lightly contacts the longitudinal member.

Notes:

When moving engine/gearbox assembly observe refrigerant pipes, hydraulic pump and second alternator if fitted.
Ensure right-hand drive shaft has sufficient clearance.
Do not damage coolant system hoses and cable pipes on cross member when swinging engine/gearbox assembly forwards.

Remove gearbox carrier -A- from engine and bevel box -B-.

Remove engine/gearbox hexagon socket head bolt (arrow).

Remove upper engine/gearbox connecting bolts (arrows A, B, C and D).

Note:

Remove cover plate when removing bolts -C- and -D-.

Assemble gearbox jack V.A.G 1383A with gearbox support 3282, adjustment plate 3282/16 for "02D" gearbox and support elements as follows:
Place adjustment plate 3282/16 on gearbox support 3282. (Adjustment plate only fits in one position).
Align arms of gearbox support according to holes in adjustment plate.

Bolt-on support elements -A-, as illustrated on adjustment plate.

Engine/gearbox is swung forwards and downwards and tilted to the left, so that the belt pulley is just touching the right-hand longitudinal member.

Place gearbox jack under vehicle, arrow symbol -B- (=>Illustration V34-2976) on adjustment plate points to front of vehicle.
Align adjustment plate parallel to gearbox and lock safety supports on gearbox.
Remove lower engine/gearbox securing bolts. Allocating the bolts => Page
34-91
.
Press gearbox off engine and remove cover plate from between engine/gearbox.
Carefully lower gearbox and swing out.
Constantly correct the gearbox position via the gearbox mounting spindles, thereby ensuring sufficient clearance to assembly carrier and support device 3184.

Notes:

If the vehicle is to be moved with the support device fitted then the following must be observed:

Screw spindle in onto stop, to lift or lower the engine/gearbox.
Exercise extreme care in the vicinity of a lift.

Transporting the gearbox

When transporting the gearbox and also when setting up gearbox support 3282, the gearbox lifting beam 3336 should be used.

Bolt gearbox lifting device 3336 to clutch housing.

Set support beam on sliding piece with locking pin (arrow).

No. of holes visible = 15

Take gearbox out with workshop crane and gearbox lifting device 3336.

Installing

When replacing gearbox, the speedometer sender and gear selector lever must be transferred to the new assembly.
When replacing gearbox mounting allocate according to parts catalogue.
Clean input shaft splines and lightly grease with G000 100 grease.

Before installing gearbox, press clutch release lever towards gearbox housing and secure with assembly bolt or M 8 x 35 bolt. Remove after gearbox has been installed. The hole must then be sealed with a plug.
Check whether dowel sleeves for aligning engine/gearbox are fitted in cylinder block, install if necessary.
Assemble gearbox jack V.A.G 1383A with gearbox support 3282, adjustment plate 3282/16 for "02D" gearbox and support elements as follows:
Place adjustment plate 3282/16 on gearbox support 3282. (Adjustment plate only fits in one position).
Align arms of gearbox support according to holes in adjustment plate.

Bolt-on support elements -A-, as illustrated on adjustment plate.
Place gearbox on gearbox jack.
Align adjustment plate and gearbox parallel with one another and lock safety supports on gearbox.

Place gearbox jack under vehicle, arrow symbol -B- (=>Illustration V34-2976) on adjustment plate points to front of vehicle.
Alternatively swing in and raise engine/gearbox assembly. The right-hand drive shaft is to be guided so that it bears on the gearbox drive flange.

Notes:

When moving engine/gearbox assembly observe refrigerant pipes, hydraulic pump and second alternator if fitted.
Ensure right-hand drive shaft has sufficient clearance.

When replacing the gearbox ensure that the intermediate plate is correctly positioned.

Install engine/gearbox lower securing bolts and tighten to prescribed torque; Allocation and torque setting of bolts => table Page
34-92
.
Remove gearbox mounting 3282 from gearbox.
Install engine/gearbox upper connecting bolts (arrows A, B, C and D) and tighten to torque setting =>table Page
34-92
.

Note:

Install cover plate when installing bolts -C- and -D-.

Install engine/gearbox hexagon socket head bolt (arrow) and tighten to torque setting =>table Page
34-92
.

Fit gearbox carrier -A- to engine and bevel box -B- => Page
34-129
.

Vehicles with hydraulic clutch control

Install slave cylinder and tighten bolts -arrows- to torque setting => Page
30-9
, item
14
, do not open system.

Note:

Do not depress clutch pedal.

Vehicles up to 12.95

Install engine/gearbox mountings stress-free, as follows:

Fit bolt for rear gearbox mounting.
Before fitting the bolts to secure the left-hand mounting bracket to the body ensure that the engine mounting pin and the support device spindle (arrow), are as much as possible, in line.

Before lifting engine/gearbox, tighten bolts of bearing block -A- (arrows 2) to prescribed torque => Page
34-91
.

Ensure that the bonded rubber mounting lugs (arrow) locate in the bearing bracket.
After lifting engine/gearbox assembly(arrow 1, illustration V34-2265), tighten bolt to torque setting => Page
34-91
.
Tighten gearbox rear mounting to torque setting =>Page
34-91
.

Warning!
Do not remove support device 3184 until the bolts securing the left-hand mounting bracket have been securely tightened.
Vehicles from 01.96

Before lifting engine/gearbox, tighten bolts of bearing block (arrows 2) to torque setting => Page
34-91
.
After lifting engine/gearbox assembly,tighten nuts (arrows 1) to torque setting=>Page
34-91
.

Warning!
Do not remove support device 3184 until the bolts securing the left-hand mounting bracket have been securely tightened.
Continued for all vehicles

Disconnect engine support 3227 from engine block.
Install flexible couping, heat shield and front propshaft to gearbox => Page
39-100
.

Vehicles from 01.96

Install pendulum support -1- and tighten bolts -arrow A- and -arrow B- to prescribed torque.

=> Axles, steering, suspension from January 1996; Repair group 40; I - Removing and installing subframe, anti-roll bar, torsion bar, wishbone and shock absorber
Axles, steering, suspension from January 1996
I - Removing and installing subframe, anti-roll bar, torsion bar, wishbone and shock absorber

Note:

Install engine/gearbox mountings stress-free.

=> Repair group 10; Removing and installing engine.
5-speed manual gearbox 02D four-wheel drive
Removing and installing engine.

Continued for all vehicles

Fit front exhaust pipe to catalyst or front silencer.

=> 5-Cyl. Diesel engine, Mechanics; Repair group 26; Removing and installing parts of exhaust system.
5-Cyl. Diesel engine, Mechanics
Removing and installing parts of exhaust system.

=> 5-Cyl. Diesel engine, Mechanics; Repair group 26; Removing and installing parts of exhaust system
5-Cyl. Diesel engine, Mechanics
Removing and installing parts of exhaust system

Vehicles with air conditioner:

Install air conditioner compressor

=> Heating, air conditioning system; Repair group Gr. 87

Resecure refrigerant pipework (illustration V34-2987, Page
34-69
).

Warn
The air conditioning refrigerant circuit must not be opened. The refrigerant hoses are prone to kinking.
Installing alternator.

=> Electrical system; Repair group 27
Electrical system

Fit ribbed V-belts, when doing this, ensure correctly seated in belt pulleys.

=> 5-Cyl. injection engine Mechanics; Repair group Gr. 13

=> 5-Cyl. diesel engine Mechanics; Repair group 13
5-Cyl. diesel engine Mechanics

Vehicles with mechanical clutch control

Hook clutch cable onto gearbox and gearbox mounting bracket => Page
30-35
.

Continued for all vehicles

Install selector mechanism to gearbox as follows:

Tighten mounting bracket with gate rod to torque setting =>Page
34-14
, item
15
(arrow 3).
Press front selector rod on gearbox selector lever (arrow 2).
Tighten swivel head to torque setting => Page
34-15
, item
18
(arrow 1).
Install starter motor/wiring.

=> Electrical system; Repair group 27; Starter motor; Removing and installing starter motor
Electrical system
Starter motor
Removing and installing starter motor

Install all electrical connections on gearbox and starter motor.

=> Electrical system; Repair group 27; Starter motor; Removing and installing starter motor
Electrical system
Starter motor
Removing and installing starter motor

Tighten coolant pipe at starter (arrows) (from expansion tank to water pump).
Install wiring harness to pipe.
If fitted, secure retainers for electrical wiring to coolant hoses.
Fit speedometer drive shaft cable or connector and speedometer sender.
Install earth strap to gearbox and mounting bracket.
Install left-hand drive shaft.

=> Running gear; Repair group 40; Servicing front suspension; Removing and installing wheel bearing and driveshaft
Running gear
Servicing front suspension
Removing and installing wheel bearing and driveshaft

=> Running gear, axles, steering from January 1996; Repair group 40; III - Removing and installing wheel bearing and drive shaft
Running gear, axles, steering from January 1996
III - Removing and installing wheel bearing and drive shaft

Bolt right-hand drive shaft to flange shaft (torque setting =>Page
34-91
).

Install bolt for right and left shock absorber/anti-roll bar coupling rod and tighten to torque setting =>Page
34-91
.

Connect left-hand lower wheel bearing housing swivel joint bolted connection and tighten to torque setting =>Page
34-91
.
Checking gear oil in gearbox and bevel box =>Page
34-132
.
Fully depress clutch pedal, at least 5 times, onto stop on vehicles with mechanical clutch control then check function of adjustment mechanism => Page
30-38
.
Adjust gear change mechanism => Page
34-27
.
Install noise insulation tray below engine/gearbox.

Vehicles from 01.96

Pretension torsion bar with special tool 3257 to dimension -a- (=> Page
34-65
).

=> Running gear, axles, steering from January 1996; Repair group 40; I - Removing and installing subframe, anti-roll bar, torsion bar, wishbone, shock absorber; Removing and installing torsion bar/Adjusting torsion bar
Running gear, axles, steering from January 1996
I - Removing and installing subframe, anti-roll bar, torsion bar, wishbone, shock absorber
Removing and installing torsion bar/Adjusting torsion bar

Install front wheels (torque setting =>Page
34-91
).

Vehicles up to 12.95

With the vehicle resting on its wheels remove vehicle support 3250

=> Running gear; Repair group 40; Servicing front suspension
Running gear
Servicing front suspension

Continued for all vehicles

Refit radiator (opposite to direction of arrow) and secure with bolts -1-.
Reconnect earth strap to battery.

=> Electrical system; Repair group 27; Battery; Removing and installing battery
Electrical system
Battery
Removing and installing battery

Install battery covering.

Note:

Note radio coding for vehicles with coded radio.

Tightening torques

Vehicles up to 12.95

Gearbox to engine up to 01 01 6

Item · Bolt · Qty. · Nm
11) · M 12 x 60 · 2 · 80
2 · M 12 x 60 · 1 · 80
3 · M 12 x 60 · 1 · 80
4 · M 12 x 100 · 1 · 80
5 · M 12 x 130 · 1 · 80
6 · M 8 x 45 · 2 · 25
72) · M 8 x 45 · 1 · 25

1)
Additionally for flywheel cover plate

2)
Tighten from engine side

Items A + B - Fitting sleeves

Vehicles from 01.96

Gearbox to engine from 02 01 6

Item · Bolt · Qty. · Nm
11) · M 12 x 130 · 1 · 80
21) · M 12 x 60 · 1 · 80
3 · M 12 x 60 · 1 · 80
4 · M 12 x 60 · 1 · 80
5 · M 12 x 100 · 1 · 80
6 · M 12 x 130 · 1 · 80
7 · M 8 x 45 · 2 · 25
82) · M 8 x 45 · 1 · 25

1)
Additionally for flywheel cover plate

2)
Tighten from engine side

Items A + B - Fitting sleeves

Left-hand gearbox mounting for vehicles up to 12.95

Bolt -arrow 1- · 65 Nm
Bolts -arrows 2- · 65 Nm

Left-hand gearbox mounting for vehicles from 01.96

Nuts -arrows 1- · 55 Nm
Bolts -arrows 2- · 50 Nm + 90°

Rear gearbox mounting for vehicles up to 12.95

Bolts -A- (M12) · 100 Nm
Bolts -B- (M10) · 40 Nm
Bolts -C- (M16) · 200 Nm

Sender to speedometer drive · 10 Nm

Lower wishbone to wheel bearing housing on vehicles up to 12.95

=> Running gear; Repair group 40; Servicing front suspension; Removing and installing upper and lower wishbones
Running gear
Servicing front suspension
Removing and installing upper and lower wishbones

Lower wishbone to wheel bearing housing on vehicles from 01.96

=> Running gear, axles, steering from January 1996; Repair group 40; II - Removing and installing upper and lower wishbones
Running gear, axles, steering from January 1996
II - Removing and installing upper and lower wishbones

Shock absorber to wishbone on vehicles up to 12.95

=> Running gear; Repair group 40; Servicing front suspension; Removing and installing subframe, anti-roll bar, torsion bar and wishbone
Running gear
Servicing front suspension
Removing and installing subframe, anti-roll bar, torsion bar and wishbone

Shock absorber to wishbone on vehicles from 01.96

=> Axles, steering, suspension from January 1996; Repair group 40; I - Removing and installing subframe, anti-roll bar, torsion bar, wishbone and shock absorber
Axles, steering, suspension from January 1996
I - Removing and installing subframe, anti-roll bar, torsion bar, wishbone and shock absorber

Driveshaft to flanged shaft and wheel hub on vehicles up to 12.95

=> Running gear; Repair group 40; Servicing front suspension; Removing and installing wheel bearing and driveshaft
Running gear
Servicing front suspension
Removing and installing wheel bearing and driveshaft

Driveshaft to flanged shaft and wheel hub on vehicles from 01.96

=> Running gear, axles, steering from January 1996; Repair group 40; III - Removing and installing wheel bearing and drive shaft
Running gear, axles, steering from January 1996
III - Removing and installing wheel bearing and drive shaft

Wheel bolts to wheel hub on vehicles up to 12.95

=> Running gear; Repair group 40; Servicing front suspension; Removing and installing wheel bearing and driveshaft
Running gear
Servicing front suspension
Removing and installing wheel bearing and driveshaft

Wheel bolts to wheel hub on vehicles from 01.96

=> Running gear, axles, steering from January 1996; Repair group 44; Wheel bolt torque settings
Running gear, axles, steering from January 1996
Wheel bolt torque settings