Removing and installing gearbox, Golf 2009 ► vehicles with all-wheel drive — VW

🔧 Engine codes this applies to

📋 Procedure

1. Remove manual gearbox together with bevel box.
2. Check whether a coded radio is fitted. If so, obtain anti-theft code.
3. With ignition switched off, disconnect battery earth strap Electrical system27Starter, current supply, CCS; Disconnecting and connecting battery.
4. If engine cover panel blocks access, remove engine cover panel.
5. Remove complete air filter housing if it is near battery 23Repairing diesel direct injection system or 24Repairing injection system.

6. Remove battery and battery tray Electrical system27Starter, current supply, CCS; Removing and installing battery.
7. Remove lines (A) from bracket (B).
8. Remove securing clip (1) for gear selector cable from gearbox selector lever (2) and pull cable off pin (arrow).
9. Releasing cable end-piece from gate selector cable
10. Pull locking mechanism forward to stop in (direction of arrow 1) and then lock by turning to left in (direction of arrow 2).
11. Push relay lever forwards ((direction of arrow 3)).
12. As work procedure is continued, remove relay lever together with cable end-piece.
13. Remove cable support bracket from gearbox (arrows), lay to side and secure with wire.
14. Clamp off supply hose to master cylinder using hose clamp3094.
15. Clamp off hose of pipe/hose assembly (A) to slave cylinder using hose clamp3094.
16. Pull out clip (arrow) for pipe/hose assembly or pipeline to stop.
17. Pull pipe/hose assembly or pipeline out from slave cylinder bleeder and seal.
18. Tie up pipe/hose assembly.
19. ⚠ Do not operate clutch pedal any more. — Remove earth strap (1) from top starter bolt.
20. Disconnect connector (2) for reversing light switch F4.
21. Remove upper engine/gearbox connecting bolts (arrows).
22. Then remove upper securing bolt on starter.
23. Bolt bracket T10346 to rear of the 3 mounting holes for battery tray.
24. To do this, use a collar bolt M6 x 80 or a securing bolt for battery tray.
25. Remove foam elements from upper edges of left and right wings.
26. If there are hose and cable connections in area of engine support eye for support bracket10-222 A, remove these now.
27. Set up support bracket10-222 A in front of bonnet support.
28. Use:
29. Position adapter10-222 A /8:
30. Connect engine and bracket to support bracket T10346.
31. Take up weight of engine/gearbox assembly and support bracket on spindles.
32. With vehicle standing on its wheels, loosen collar bolts (arrow) no more than 90°; otherwise wheel bearing will be damaged Running gear, axles, steering40Removing and installing drive shafts.
33. Raise vehicle.
34. Remove noise insulation General body repairs, exterior50Noise insulation.
35. Remove lower part of front right and left wheel housing liner General body repairs, exterior66Wheel housing liner.
36. If fitted, unscrew front left vehicle level sender G78 from transverse link Running gear, axles, steering40Subframe, anti-roll bar, suspension links; Removing and installing front left vehicle level sender G78.
37. Remove bracket from starter.
38. Remove starter Electrical system27Starter; Removing and installing starter.
39. Disconnect connector (1) for oil level and oil temperature sender G266.
40. Remove left charge air hose (arrow 1) and (arrow 2)21Charge air system with turbocharger.
41. Remove right charge air hose from charge air cooler 21Charge air system with turbocharger.
42. Remove cowling (arrow) together with radiator fans 19Parts of cooling system.
43. Remove front exhaust pipe (arrow) from turbocharger, and secure it in place 26.
44. Remove pendulum support.
45. Remove left coupling rod from anti-roll bar, and lay it to one side Running gear, axles, steering40Front wheel suspension; Repairing front wheel suspension.
46. Remove left drive shaft Running gear, axles, steering40Removing and installing drive shafts.
47. If fitted, remove drive shaft heat shield (arrows)Running gear, axles, steering40Repairing drive shafts - overview of drive shafts.
48. Remove right drive shaft from gearbox, and tie it up Running gear, axles, steering40Removing and installing drive shafts.
49. Fix subframe in position prior to removal Running gear40Subframe, anti-roll bar, suspension links; Fixing subframe and brackets in position.
50. Remove subframe with pendulum support, anti-roll bar, brackets and suspension links Running gear40Subframe, anti-roll bar, suspension links; Assembly overview - subframe, anti-roll bar, suspension links.
51. Mark position of propshaft with flexible coupling relative to bevel box flange with paint.
52. Remove propshaft from bevel box (arrows)Propshaft and rear final drive, Volkswagen R Gmb H39Final drive, rear differential; Removing and installing propshaft.
53. Push back front propshaft tube onto stop.
54. If small cover plate (A) for flywheel is present, remove it (arrows).
55. Remove hexagon bolts (arrows) on left engine/gearbox mounting (2) from bracket (1).
56. Lower gearbox about 60 mm, dimension (a), by adjusting spindles attached to engine. [Note: Observe connecting lines, hoses and radiator when moving engine/gearbox assembly.]
57. Remove bracket (1) from gearbox (arrows).
58. Remove relay lever together with cable end-piece.
59. Remove gearbox selector lever from selector shaft.
60. Remove engine/gearbox connecting bolt (1). [Note: Loosen engine/gearbox connecting bolts (2) and leave them installed just hand-tight.]

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