Removing and installing gearbox - Vehicles with 6 cylinder fuel injection engine - — VW

006
Removing

With the vehicle resting on its wheels loosen left-hand wheel hub/drive shaft bolt and left and right-hand wheel securing bolts.

Note:

Note radio coding for vehicles with coded radio.

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
Electrical system

Remove air cleaner upper section to do this loosen clips -A- and hose -B-.
Remove air cleaner lower section.

Remove trim for air guide (arrows).

Press pipe off above mounting eye for support device 10- 222 A (arrow).

Remove vacuum hose (arrow -A-) to brake servo at intake manifold.
Pull connector (arrow -B-) off intake air temperature sender G72.

Fit support device 10-222A together with legs 10-222 A/5.

Bolt legs 10-222 A/5 to body (arrows).
Take weight of engine/gearbox assembly on the spindles.

Remove nuts for right-hand engine mounting (arrows).

Remove insulation tray below engine/gearbox, if fitted.
Remove starter.

=> Repair group 27; Removing and installing starter.
5-speed manual gearbox 006
Removing and installing starter.

Lever clip (arrow -A-) for pipe out from slave cylinder (direction of arrow), pull pipe (arrow -B-) out and seal with 10 mm plug.

Remove both wheels

Remove/loosen left and right-hand wheel mountings as follows:

Press track rod off steering arm.

1 -
Hooks (commercially available) e. g. Kukko No. 1-90
2 -
Puller (commercially available) e.g. Kukko No. 20-10

Tie up track rod

Separate left and right-hand bolted connection for wheel bearing housing/lower swivel joint.

Remove left and right-hand coupling link -1- on shock absorber.
Detach brake hose and, if fitted, ABS sensor cable from retainers on shock absorber.

Place drip tray underneath.
Lever left-hand drive shaft out of gearbox and pull out of wheel hub.

Insert sealing cap 3394 into gearbox.

Vehicles up to January 97

Pull right-hand drive shaft out of centre bearing by tugging outwards on wheel mounting.
Tie-up drive shaft as high as possible. Do not damage paint on drive shaft.
Unbolt centre bearing from mounting on engine block (arrows -A-) and pull with axle shaft (arrow -B-) out of gearbox, lever out if necessary.
Insert sealing cap 3394 into gearbox.

Vehicles from January 97

Pull right-hand drive shaft out of centre bearing by tugging outwards on wheel mounting.
Tie-up drive shaft as high as possible. Do not damage paint on drive shaft.
Unbolt axle shaft bearing (arrows) and pull axle shaft out of gearbox.

Remove engine/gearbox support -arrows 1 to 3-.
Insert sealing cap 3394 into gearbox.

Continuation for all vehicles

Remove pendulum support -1-, to do this remove bolt and nuts -A-.

Note:

The pendulum support can be secured to the assembly carrier with one bolt or with three bolts.

Separate gearbox mounting, to do this remove bolts -A- and -B-.
Push engine/gearbox assembly as far as possible to right.
Tilt engine/gearbox assembly, to do this raise right-hand spindle and lower left-hand spindle.

Remove mounting from gearbox console (arrows).

Pull connector off road speed sender (arrow).

Remove flywheel cover plate.

Lever gear selector cable -A- and gate selector off and press out from mounting on gearbox.
Push pipework between master and slave cylinder out of mounting on gearbox.

Assemble gearbox jack with gearbox support 3282, adjustment plate 3282/21 for "006", gearbox and support elements as follows:

Place adjustment plate 3282/21 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.

Remove engine/gearbox securing bolts (arrows).

Place gearbox jack under vehicle, arrow symbol -B- (=> Illustration N34-0296 on previous page) on adjustment plate points to front of vehicle.
Align adjustment plate parallel to gearbox and secure gearbox with bolt.

Remove engine/gearbox securing bolts (arrows).

Press gearbox off dowels and lower until the reversing light connector (arrow) can be reached.
Pull reversing light connector off (arrow).
Lower gearbox carefully.
Charge position of gearbox in area of assembly carrier and left-hand body when lowering via gearbox jack spindle.

Transporting the gearbox

Special tool 3336 may be used to transport the gearbox and also when setting up gearbox mount 3282.

Bolt gearbox lifting device 3336 to clutch housing.

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

No. of holes visible = 7

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

Installing

Clean input shaft splines and lightly grease with G000 100 grease.

The clutch plate must be able to slide lightly to and fro on the input shaft.

Check whether dowel sleeves for aligning engine/gearbox are fitted in cylinder block, install if necessary.
Assemble gearbox jack with gearbox support 3282, adjustment plate 3282/21 for "006" gearbox and support elements as follows:

Place adjustment plate 3282/21 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 and secure with a bolt.

Place gearbox jack under vehicle, arrow symbol -B- (=> Illustration N34-0296 on previous page) on adjustment plate points to front of vehicle.

Reconnect reversing light connector (arrow).
Install gearbox, press engine slightly forward if necessary.
Install all engine/gearbox securing bolts.

Press gear selector cable and gate selector cable in mounting on gearbox onto stop.

Installation position:

The gear selector cable crosses over the gate selector cable.

Press gear selector cable -A- onto gear stick lever.
Press gate selector cable -B- onto gate selector lever.

Press pipe work into retainer on gearbox and insert into slave cylinder.
Press clip -A- for pipe -B- in.

Install mounting to gearbox console (arrows).

Align engine/gearbox in installation position.
Assemble gearbox mounting. To do this screw bolts -A- and -B- in.
Remove support bar 10-222A.

Warning!
Do not remove support bar 10-222A until the bolts securing the left-hand gearbox mounting have been tightened to torque setting.
Pendulum support to gearbox

For start of production a steel pendulum support was produced with two bushes for mounting to subframe - Length of bushes = 90 mm.

After a short run-up period the support will be substituted for an aluminium support -1- with one bush (arrow) - Length of bush = 90 mm.

Due to modifications to pendulum support mounting a shorter bush has been introduced - Length of bush = 85 mm.

Allocate pendulum support to subframe mounting:

Width of mounting · Identification · Length of bush(es) (arrow) in pendulum support · Number of bushes (arrow) in pendulum support
90 mm · 3 holes · 90 mm · 11) or 2
85 mm · 1 hole · 85 mm · 1

1)Secure pendulum support with one bush into front subframe drilling.

From 09.03.98 a longer bolt -A- has been introduced. The drilling in the pendulum support has been adapted to the longer bolt.

Allocation

Dimension -a- · Tightening torque
New: · 88 mm · Tighten to 60 Nm + turn / 90°further / - Always renew bolt
Previously: · 78 mm · 70 Nm

The new bolt cannot be installed in the old pendulum support.

If the pendulum support is renewed, the new bolt -A- must be installed.

Reconnect road speed sender connector (arrow).
Install flywheel cover plate.
Bolt on earth wire.
Install starter.

=> Repair group 27; Removing and installing starter.
5-speed manual gearbox 006
Removing and installing starter.

Take sealing caps 3394 out from shaft openings.
The securing ring -A- must be replaced before installing left-hand shaft.
Push left-hand shaft in (direction of arrow), carefully drive in with synthetic head hammer if necessary.

Vehicles up to January 97

Replace securing ring on splines for right-hand drive shaft before installing axle shaft.
Carefully insert axle shaft into gearbox, do not damage sealing ring.
Bolt axle shaft bearing on securely (arrows).
Push right-hand drive shaft onto axle shaft splines, carefully drive on with a synthetic head hammer if necessary.

Vehicles from January 97

Fit support onto engine/gearbox.
First tighten bolts -arrows 1 to 3- in ascending order hand tight, then tighten to tightening torque.
Replace securing ring of axle shaft splines.
Carefully insert axle shaft into gearbox, do not damage sealing ring.

Bolt axle shaft bearing on securely (arrows).
Push right-hand drive shaft onto axle shaft splines, carefully drive on with a synthetic head hammer if necessary.

Continuation for all vehicles

Install left and right-hand coupling links -1- to shock absorber.
Press brake hose and, if fitted, the ABS sensor cable in retainer on shock absorber.

Assemble left and right-hand bolted connection for wheel bearing housing/lower swivel joint.
Press left and right-hand track rods on steering arm.
Install both wheels.

Install insulation tray below engine/gearbox, if fitted.
Install nuts fo right-hand engine mounting.
Install air cleaner.
Reconnect earth strap to battery.
Bleed clutch system.
Check gearbox oil =>Page
34-89
.
Adjust gear change linkage => Page
34-26
.

Note:

Note radio coding for vehicles with coded radio.

Tightening torques

Gearbox to engine

Pos. · Bolt · Qty. · Nm
1 · M 12 x 50 · 4 · 80
2 · M 12 x 60 · 1 · 80
31) · M 7 x 12 · 2 · 10

1)
Flywheel cover plate

Items A + B - Dowel sleeves

Vehicles up to January 97

Centre bearing to bracket (arrows) · 27 Nm

Vehicles from January 97

Support to engine/gearbox

Bolt -1- · 45 Nm
Bolt -2- · 20 Nm
Bolt -3- · 45 Nm

First tighten bolts -arrows1 to 3- in ascending order hand tight, then tighten to tightening torque.

Axle shaft bearing to support

Bolts (arrows) · 20 Nm

Continuation for all vehicles

Gearbox to body

Bolts -A- · 20 Nm
Nut on bolt -B- · 100 Nm

Bracket to gearbox console (arrow) · 90 Nm

Bolts and nuts -A- for steel pendulum support -1- · 100 Nm

Nut -B- for aluminium pendulum support -1- · 100 Nm

Shock absorber to coupling link · 100 Nm

Wheel bearing housing to lower swivel joint · 55 Nm
Drive shaft to wheel hub · 150 Nm and turn 90°further

Wheel bolts to wheel hub · 140 Nm

Track rod to steering arm · 30 Nm and turn 90°further

Engine mounting nuts (arrows) · 50 Nm