Removing gearbox, as of 08.2010► — VW

Removing gearbox, as of 08.2010►
Special tools and workshop equipment required
Support bracket
10-222A
Adapter
10-222A/30
Adapter
10-222A/3
Hook
10-222A/2
Adapter
10-222A/16
Hook
10 - 222 A /10
Pin
3282/29
Pin
3282/48
Support
3282/59
Gearbox support
3282
Adjustment plate
3282/39
Engine and gearbox jack
V.A.G 1383A
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Gearbox mounting support
3336
Grease
G 000 450 02
Grease
G 000 100
With ignition switched off, disconnect battery earth strap.
Electrical system
Rep. gr.
27
Battery; Disconnecting and connecting battery
Remove engine cover panel from engine.
Remove complete air filter housing.
Rep. gr.
23
Removing and installing air filter
Remove battery, battery cover and battery tray
Electrical system
Rep. gr.
27
Battery; Removing and installing battery
.
Remove securing clip
arrow 1
for gear selector cable from gearbox selector lever
A
.
Remove securing clip
arrow 2
for gate selector cable from relay lever
B
.
Pull gear selector cable and gate selector cable off pins.
Pull securing clip
arrow 3
off relay lever
B
and remove relay lever.
Remove gearbox selector lever
A
by removing nut
arrow 4
.
Remove cable support bracket from gearbox
arrows
.
Then use cable tie to tie up gear selector cable and gate selector cable.
Remove retainer
B
from gearbox and pull off from pipe/hose assembly
A
.
Then remove gearbox support
arrow A
.
Note
There is no need to remove slave cylinder with securing bolts
arrows B
.
Pull clip
A
for pipe/hose assembly out of slave cylinder to stop.
Pull pipe/hose assembly out of retainer
C
on gearbox.
Pull pipe/hose assembly
B
out of slave cylinder and seal opening.
Note
Do not depress clutch pedal.
Remove earth strap at upper engine/gearbox connecting bolt.
Pull off reversing light connector
arrow 1
.
Now remove connector
arrow 2
and wire
arrow 3
from starter.
Then remove upper securing bolt on starter.
Remove upper engine/gearbox connecting bolts.
Remove filler pieces from upper edge of left and right wings.
If there are hose and cable connections in area of engine support eye for
support bracket
10-222A
, remove these now.
Set up
support bracket
10-222A
together with
adapters
10-222A/30
,
adapter
10-222A/3
and
adapter
10-222A/16
before gas strut for bonnet.
Attach
hook
10-222A/10
at front right of engine.
Now attach
additional hook
10-222A/2
to rear left of engine
arrow
.
Connect
hook
10-222A/2
using
adapter
10-222A/16
.
Take up weight of engine/gearbox assembly on spindles.
Raise vehicle.
Remove any noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation
.
Remove front left wheel housing liner
General body repairs, exterior
Rep. gr.
66
Removing and installing wheel housing liner; Front wheel housing liner
.
Then remove all lines from gearbox.
Remove drive shaft shield from engine
arrows
, if fitted.
Separate exhaust system at double clamp, and unbolt exhaust pipe bracket from subframe
arrows
Rep. gr.
26
Emission control
.
Disconnect drive shafts from flange shafts and tie up as high as possible, being careful not to damage surface protection.
Remove pendulum support
arrows A
,
B
and
C
.
Remove right-hand engine mounting from engine
arrows
.
Rep. gr.
10
Assembly mountings
Remove hexagon bolts
arrows
for left assembly mounting from gearbox mounting.
Tilt engine/gearbox assembly by lowering it via spindles of
support bracket
10-222A
.
Note
Be careful of all lines when lowering gearbox.
Lower threaded spindle of
adapter
10-222A/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.
Securing bolts
arrows
for gearbox bracket
A
must be accessible.
Remove gearbox bracket
A
arrows
.
If small cover plate
A
for flywheel behind the right flange shaft
arrows
is installed, remove it.
Remove exhaust system strut
1
from gearbox
arrow
.
Remove starter.
Electrical system
Rep. gr.
27
Starter
To remove gearbox
“0A4”
, set up
gearbox support
3282
with
adjustment plate
3282/39
.
Insert
gearbox support
3282
in
engine and gearbox jack
V.A.G 1383A
.
Align arms of
gearbox support
according to holes in
adjustment plate
.
Screw in
support elements
A
and
C
on
adjustment plate
as shown.
Position
engine and gearbox jack
under vehicle. Arrow
B
on
adjustment plate
points in direction of vehicle travel.
Align
adjustment plate
parallel to gearbox and lock safety support on gearbox.
Then screw
pin
3282/39
into hole on gearbox for securing bolt of pendulum support.
Remove lower engine/gearbox connecting bolts.
Press gearbox off dowel sleeves and carefully swing towards subframe.
Have a second mechanic push engine forwards slightly.
Lower gearbox carefully. While doing this, guide right flange shaft
A
past intermediate plate and flywheel as shown.
Tilt gearbox in area of differential downwards in direction of subframe.
When lowering gearbox, change position of gearbox using spindles of
gearbox support
3282
.
Note
Be careful of all lines when lowering gearbox.