Removing gearbox, vehicles with 1.8 l/125 kW petrol engine — VW

🧭 Before you start

Fits: platform codes 5C7, 5C1

• Opens: gearbox oil
• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: T40091/1, locking pin

Don't miss

• Remove clutch slave cylinder (arrows B), lay it to one side, and secure it with wire. Do not open hydraulic system.
• The flexible joint of the front exhaust pipe must not be bent more than 10° – danger of damage.
• The thrust piece T10148 is intended to protect the right oil seal and the gearbox against dirt.Instead of the spindle (A), an M8x105 mm bolt can be screwed hand-tight into the threaded piece of the differential.
• Connect adapter10 - 222 A /31-1 and adapter10 - 222 A /31-2 to support bracket10 - 222 A(as shown in illustration), but do not tighten them yet.
• Slightly take up weight of engine/gearbox assembly on spindles10 - 222 A /11; do not lift.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Disconnect battery earth strap Electrical system27Battery; Disconnecting and connecting battery.
2. Remove engine cover panel 10Engine cover panel; Removing and installing engine cover panel.
3. Remove complete air filter housing 24Air filter; Removing and installing air filter housing.
4. Remove battery and battery tray Electrical system27Battery; Removing and installing battery tray.
5. Pull locking mechanism of gate selector cable forward as far as stop in (direction of arrow 1) and then lock by turning it in (direction of arrow 2).

6. Push relay lever forwards in direction of (arrow 3), at the same time pulling out the gate selector cable.
7. Pull off clip (arrow 1) and remove relay lever together with cable end-piece.
8. Remove circlip (arrow 2) and pull gear selector cable off gearbox selector lever (A).
9. Remove gearbox selector lever (A) by removing nut (arrow 3).
10. Remove cable support bracket (1) from gearbox (arrows).
11. Tie off cables to one side together with cable support bracket.
12. Release wire (2) from bracket (1), and lay it to one side.
13. Undo bolt (3) and remove bracket.
14. Then remove gearbox support (arrow A).
15. Remove clutch slave cylinder (arrows B), lay it to one side, and secure it with wire. Do not open hydraulic system.
16. ⚠ Risk of damage to clutch slave cylinder.Do not press the clutch pedal if the clutch slave cylinder has been removed from the gearbox with the pipe/hose assembly still attached. — Pull connector (arrow 1) off reversing light switch F4.
17. Now remove connector (arrow 2) and wire (arrow 3) from starter.
18. Remove earth wire from upper securing bolt for starter (arrow).
19. Then, unscrew upper securing bolt from starter (arrow).
20. Remove bolts accessible from above (1) and (2) from gearbox-to-engine connection.
21. Raise vehicle and remove front left wheel.
22. Remove noise insulation General body repairs, exterior66Noise insulation; Assembly overview - noise insulation.
23. Remove front left wheel housing liner General body repairs, exterior66Wheel housing liner; Assembly overview - front wheel housing liner.
24. Pull connector (arrow) off gearbox neutral position sender G701.
25. Remove nut (arrow) and remove retainer for electrical lines.
26. Remove lower securing bolt from starter and remove starter Electrical system27Starter; Removing and installing starter.
27. Remove radiator cowl with radiator fan (arrow)19Radiator, radiator fan; Removing and installing radiator cowl.
28. Unscrew bolt (2), and remove clip 26Emission control; Assembly overview – emission control.
29. Unscrew nuts (3) for catalytic converter bracket from subframe.
30. Tie up front exhaust pipe to one side. [Note: The flexible joint of the front exhaust pipe must not be bent more than 10° – danger of damage.]
31. Remove heat shield above right drive shaft (arrows).
32. Disconnect left and right drive shafts from flange shafts of gearbox.
33. Push up left and right drive shafts and secure with cable ties or tensioning straps T10038, for example.
34. Remove bolt (arrow) for right flange shaft by screwing two bolts into flange and counterholding flange shaft with a assembly lever.
35. Remove flange shaft. [Note: Before removing flange shaft, check oil seal for leaks. If oil seal leaks, it must be renewed during installation .If gear oil escapes during removal of the flange shaft: with gearbox and flange shaft installed, drain gear oil and top it up again .]
36. Screw spindle (A) from assembly tool3066 into threaded piece of differential.
37. Insert thrust piece T10148 and secure with nut (B). [Note: The thrust piece T10148 is intended to protect the right oil seal and the gearbox against dirt.Instead of the spindle (A), an M8x105 mm bolt can be screwed hand-tight into the threaded piece of the differential.]
38. Unscrew bolt (1) for pendulum support (4) from subframe (5).
39. Then remove bolts (2) and (3).
40. Remove pendulum support.
41. Remove plenum chamber cover General body repairs, exterior50Plenum chamber cover; Removing and installing plenum chamber cover.
42. Remove lock carrier trim General body repairs, exterior50Lock carrier, Assembly overview - lock carrier.
43. Release catch (arrow), and pull mounting (1) for engine cover panel off left engine lifting eye 10Assembly mountings; Supporting engine in installation position.
44. Unclip mounting (1) for engine cover panel from right engine lifting eye (2)10Assembly mountings; Supporting engine in installation position.
45. Unscrew bolts (arrows) for retaining brackets on left and right of lock carrier.
46. Unscrew lower supports from adapters10 - 222 A /28, and replace them with supports 10 - 222 A /28-1.
47. Fit adapters10 - 222 A /28 with supports 10 - 222 A /28-1 onto lock carrier at left and right, and screw them on using threaded holes for support arms (arrows).
48. ⚠ A 2nd mechanic is needed to place support bracket10 - 222 A on the vehicle in order to prevent the support bracket from tipping. — First, slide swivel joints T40091/3 onto square tube of support bracket10 - 222 A.
49. Connect adapter10 - 222 A /31-1 and adapter10 - 222 A /31-2 to support bracket10 - 222 A(as shown in illustration), but do not tighten them yet.
50. Fit support bracket10 - 222 A on suspension turrets with the aid of a second mechanic to prevent it from tipping.
51. Slide T40091/1 on left and right from front through 10 - 222 A /28, and fit swivel joints T40093/4 on each side.
52. Slide hook rail T40091/2 through swivel joint T40093/4 on one side, and fit both supports T40093/5.
53. Guide hook rail T40091/2 through swivel joint T40093/4 on another side.
54. Insert locking pin (1) in hook rail T40091/2, and secure with split pins.
55. Tighten all threaded connections of support bracket by hand. When doing this, adjust support bracket via adapters10 - 222 A /28 so it is parallel in height.
56. Slightly take up weight of engine/gearbox assembly on spindles10 - 222 A /11; do not lift.
57. Remove hexagon bolts (arrows) for left assembly mounting from gearbox mounting.
58. Tilt engine/gearbox assembly by lowering it via spindles of support bracket10 - 222 A.
59. ⚠ When lowering the engine/gearbox assembly, ensure that none of the components of the poly V-belt drive rest on the longitudinal member. — Remove gearbox bracket (A)(arrows).
60. Insert gearbox support3282 in engine and gearbox jackV.A.G 1383A.

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