Removing and installing gearbox with power take-off — VW

Special tools and workshop equipment required

2041 hub cover puller
V.A.G 1331 torque wrench 5...50 Nm
V.A.G 1332 torque wrench 40...250 Nm
V.A.G 1383 A engine/gearbox support

Removing

Note:

Obtain coding on vehicles with coded radio.

Disconnect battery earth strap when ignition is switched off.
Pull up bellows -2- on shift lever -1- and unscrew bolt -3- with washer -4-

Prise shift lever -1- off gearbox shift lever or auxiliary lever.

Note:

Never release shift lever from tapered seat using hammer blows as this results in damage to the mount of the lower section of the shift lever.

Remove centre console.

=> General Body Repairs Interior; Repair group 68; Removing centre console
General Body Repairs Interior
Removing centre console

Remove maintenance hatch cover.

=> General Body Repairs External; Repair group 50; Removing cover of service opening
General Body Repairs External
Removing cover of service opening

Remove connecting bolts for engine/gearbox -arrows-.
Raise vehicle.

Unscrew power take-off propshaft (gearbox with flange) or detach connections to auxiliary unit (gearbox without flange).

Unscrew safety bracket on one side and loosen on the other side.

Mark position of propshaft and flange.
Unscrew propshaft -1- from flange -2-.

Suspend propshaft-1- from safety bracket -2-.
Arrest engine. To do this, place a wooden board approx. 2 cm thick under the engine sump oil pan on the front axle assembly carrier.

Unscrew electric cable -1- from power take-off control switch (F247)-2- and pull off.
Unscrew hydraulic pipe -3- from slave cylinder.

Remove securing bolts -arrows- of rear engine/gearbox mount.

Detach clutch slave cylinder -1- and bracket -3- for hydraulic pipe of power take-off from gearbox, remove sealing washer -2- and tie up clutch slave cylinder and hydraulic pipe.

Unscrew electric cable -1- from reversing light switch -2- (F4) and pull off.

Detach speedometer sender -1- (G22).
Unscrew earth straps from gearbox.
Remove starter.

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

Unscrew bolts for lower engine/gearbox fixing.

Support gearbox with gearbox support V.A.G 1383 A and secure with belt.
Press gearbox off engine and lower carefully.

Installing

The installation of the gearbox takes place in the reverse order.

The following work is also to be carried out.

Check whether the dowel sleeves for centring the engine/gearbox are fitted in the cylinder block and install if necessary.

In the crankshaft a needle bearing (arrow) must be fitted to guide the gearbox input shaft, install needle bearing if necessary.

=> Engine, mechanics; Repair group 13; Crankshaft group
Engine, mechanics
Crankshaft group

Clean input shaft splines and lubricate lightly with grease G 000 100.
Install starter/cables.

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

Checking gearbox oil => Page
34-12
.
Adjust selector mechanism

=> 5-speed manual gearbox 000.1 and 000.2, Repair group 34; Servicing selector mechanism

Bleeding hydraulic system of power take-off => Page
34-114
.

Tightening torques

Gearbox to engine

Vehicles with engine code letter(s): AGX (2.5l - 55 kW);
AHD (2.5l - 75 kW)
Vehicles with engine code letter(s): AGK (2.8l - 92 kW) with additional adapter ring between engine and gearbox.

Item · Bolt · Qty. · Nm
11) · M 12 x 65 · 1 · 80
2 · M 12 x 130 · 2 · 80
3 · M 12 x 65 · 7 · 80

Vehicles with engine code letter(s): AGL (2.3l - 105 kW)

Item · Bolt · Qty. · Nm
11) · M 10 x 115 · 1 · 55
2 · M 10 x 90 · 1 · 55
3 · M 10 x 60 · 8 · 55

1)
Earth strap also secured

Item A + B - dowel sleeves (both figures)

Rear gearbox/engine mount

Bolt -arrow A- · 90 Nm
Bolt -arrow B- · 45 Nm

Clutch slave cylinder

Securing bolts of slave cylinder -arrows- · 25 Nm

Shift cylinder

Hydraulic pipe -1- to shift cylinder · 15 Nm
Securing bolts -2- of shift cylinder · 13 Nm

Speedometer sender (G22) to gearbox · 8 Nm
Propshaft to gearbox flange · 70 Nm
Safety bracket of propshaft to frame · 90 Nm
Propshaft to power take-off flange · 23 Nm