Removing gearbox, vehicles with petrol engine — VW

🧭 Before you start

Fits: platform codes AU1, BX5

• Opens: brake fluid
• Timing position: the crankshaft or camshaft is set and locked during this job

Don't miss

• The relay lever must be removed before detaching the cable end-piece .
• Brake fluid must not be allowed to get onto the longitudinal member or the gearbox. If this does happen, clean the affected areas thoroughly.
• Clamping off the supply hose with the hose clamp3094 will cause a permanent deformation.However, this does not damage the supply hose.After removing the hose clamp3094, the supply hose must be returned to its original shape.
• Risk of soiling due to escaping brake fluid.Do not operate clutch pedal after detaching pipe/hose assembly from bleeder connection on clutch slave cylinder. — Unscrew upper engine/gearbox connecting bolts (arrows).
• If fitted, pull off electrical wiring in front area of web on both longitudinal members (arrow). Do not disconnect pipe/hose system.

🔩 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 (1)(arrows)Electrical system27Battery; Removing and installing battery.
5. Remove securing clip (1) for gear selector cable from gearbox selector lever (2). Pull gear selector cable off pin (arrow).

6. Releasing cable end-piece from gate selector cable
7. Pull locking mechanism as far as stop towards front in (direction of arrow 1). Then engage locking mechanism towards left in direction of (arrow 2).
8. Then push relay lever forwards ((direction of arrow 3)). [Note: The relay lever must be removed before detaching the cable end-piece .]
9. Unscrew nut (1) and bolts (2) and lay cable support bracket together with Bowden cables to one side. [Note: Brake fluid must not be allowed to get onto the longitudinal member or the gearbox. If this does happen, clean the affected areas thoroughly.]
10. Clamp off supply hose to clutch master cylinder using hose clamps, up to 25 mm3094. [Note: Clamping off the supply hose with the hose clamp3094 will cause a permanent deformation.However, this does not damage the supply hose.After removing the hose clamp3094, the supply hose must be returned to its original shape.]
11. Lay a lint-free cloth under bleeder.
12. Pull out clip (arrow) as far as stop and pull pipe/hose assembly (A) off bleeder.
13. Raise line and tie.
14. Seal open lines and connections using clean plugs from engine bung setVAS 6122.
15. ⚠ Risk of soiling due to escaping brake fluid.Do not operate clutch pedal after detaching pipe/hose assembly from bleeder connection on clutch slave cylinder. — Unscrew upper engine/gearbox connecting bolts (arrows).
16. If there are hose and cable connections in area of engine support eye for support bracket10 - 222 A, remove these now.
17. Install support bracket10 - 222 A as follows:
18. On both sides of vehicle, insert adapters10 - 222 A /29 between upper wheel housing longitudinal member and mounting plate for wing located underneath.
19. Push adapter10 - 222 A /18 and 2 connecting pieces T40091/3 onto engine support bracket10 - 222 A.
20. Secure support bracket10 - 222 A to adapters10 - 222 A /29.
21. Remove filler pipe for washer fluid reservoir of windscreen washer system Electrical system92Windscreen washer system; Removing and installing washer fluid reservoir.
22. If fitted, pull off electrical wiring in front area of web on both longitudinal members (arrow). Do not disconnect pipe/hose system.
23. Place adapters T40093/3-6 onto both longitudinal members (the figure shows the right longitudinal member).
24. If necessary, carefully unclip any pipes for air conditioning system in front area. Do not disconnect pipe/hose system Heating, air conditioning87Refrigerant circuit; System overview - refrigerant circuit.
25. Screw in spindles T40093 /3.
26. Connect spindles T40093 /3 via square tubes T40091/1 with engine support bracket10 - 222 A and tighten (⇒ previous Fig.).
27. Then, hook spindles into lifting eyes of engine, as shown in illustration above. Use shackle10 - 222 A /12, if necessary.
28. Take up weight of engine/gearbox assembly and engine support bracket on spindles.
29. Disconnect electrical connections on gearbox (front left).
30. Remove noise insulation General body repairs, exterior66Noise insulation; Assembly overview - noise insulation.
31. Remove lower part of front left wheel housing liner General body repairs, exterior66Wheel housing liner; Assembly overview - front wheel housing liner.
32. Remove starter Electrical system27Starter; Removing and installing starter.
33. Pull connector (1) off oil level and oil temperature sender G266.
34. Remove left charge air hose (1)21Charge air system; Assembly overview - charge air system.
35. Remove radiator cowl with radiator fan (arrow)19Radiator, radiator fan; Removing and installing radiator cowl.
36. If fitted, unbolt front left vehicle level sender G78 from lower suspension link Running gear, axles, steering43Vehicle level sender; Assembly overview - front vehicle level sender.
37. If fitted, remove drive shaft heat shield (arrows)Running gear, axles, steering40Drive shaft; Removing and installing drive shaft heat shield.
38. Remove right drive shaft from flange shaft, raise it high as possible and tie it up. Do not damage surface protection Running gear, axles, steering40Drive shaft; Removing and installing drive shaft.
39. Unbolt left drive shaft from flange shaft Running gear, axles, steering40Drive shaft; Removing and installing drive shaft.
40. Swivel left suspension strut outwards and support with hook 2024 A /1, as shown in illustration.
41. ⚠ Risk of accidents due to loose components of engine support.Secure rig pin and swivel joint with locking pins (arrow) and nut (1). — Raise left drive shaft as high as possible and tie it up. Do not damage surface protection Running gear, axles, steering40Drive shaft; Removing and installing drive shaft.
42. Separate exhaust system from engine and tie it up 26Exhaust pipes/silencers; Assembly overview - silencer.
43. ⚠ Risk of damage to decoupling element.Observe 26Cleansing exhaust emissions; Assembly overview - emission control. — Remove pendulum support.
44. If fitted, unscrew nut (arrow) and detach earth wire.
45. Unscrew bolts (arrows) for gearbox mounting.
46. Lower gearbox by adjusting spindles of engine support bracket10 - 222 A as far as distance (a).
47. Unscrew bolts (arrows) and remove gearbox bracket from gearbox.
48. Unscrew bolts (2) securing gearbox to engine.
49. Align arms of gearbox support according to holes in adjustment plate.
50. Attach support elements(A) to adjustment plate as illustrated.
51. Screw in pin3282/29 instead of support element(C).
52. Align adjustment plate and gearbox parallel to one another.
53. Then screw pin3282/29 into rear hole on gearbox for securing bolt of pendulum support.
54. Secure adapterVW 771/40 in threaded hole of gearbox housing as shown in figure.
55. Secure gearbox to gearbox support3282 using bolt (M10 × 20) (A).
56. Position engine and gearbox jackV.A.G 1383 A under vehicle. Arrow on adjustment plate points in direction of vehicle travel.
57. Unscrew bolt (C) securing gearbox to engine.
58. Remove remaining engine/gearbox connecting bolts.
59. Press gearbox away from engine, off dowel sleeves.
60. Have a second mechanic push engine towards front end slightly.

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