Transmission, Removing and Installing

Transmission, removing and installing





Special tools and equipment
^ 10-222 A Support
^ 10-222A/8 Support
^ 10-222 A/2 Special hook
^ 10-222 A/3 Adapter
^ 3094 Hose clamps
^ 3282 Transmission support





Special tools and equipment
^ 3282/27 Adjustment plate
^ 3282/48 Pins (Qty. 2)
^ 3282/52 Support
^ 3300 A Engine support
^ 3336 Transmission lifting beam
^ V.A.G 1331 Torque wrench
^ V.A.G 1332 Torque wrench
^ V.A.G 1383 A Engine/transmission jack

Special tools and equipment








^ V.A.S 5024 Assembly pliers
^ T10036 Support rail

Removing
^ Remove cover from engine.

Note: Check whether a coded radio is installed as during the forthcoming work sequences the battery Ground strap must be disconnected. Obtain radio code first, if necessary.

^ With ignition switched off disconnect battery Ground strap.
^ Remove battery.
^ Remove battery carrier.





^ Remove intake hose -1- - connector -2- and hose -3- from Mass Air Flow sensor.
^ Remove complete air cleaner housing by removing bolts -4- and -5-.
^ Remove intake hose -1-.





^ Remove cable support bracket from transmission (arrows).





^ Pull lock washer (arrow -1-) from gate selector cable relay lever -A-.
^ Remove gear selector cable -B- with transmission selector lever by removing nut (arrow 2).

Note: If necessary, use puller such as Kukko 20-10.

^ Remove power steering pipe (arrow -3-).





^ Pull connector off speedometer sender (arrow).





^ Remove wiring (arrow -1-) from starter.
^ Disconnect reverse light connector (arrow -2-).
^ Remove cable retainer (arrow -3-) on starter.
^ Remove upper securing bolt on starter.





^ Clamp clutch slave cylinder hose with special tool 3094.
^ Pull out clamp (arrow) and pipe/hose in direction of arrow.

Note: Do not depress clutch pedal.





^ Remove Ground strap at engine/transmission upper securing bolt.
^ Remove engine/transmission upper securing bolts.
^ Remove engine/transmission securing bolt with 18 mm socket wrench.
^ If there are hoses and cable connections in area of engine mounting eye for support 10-222A, remove these now. Z -





^ Fit support bar 10-222A together with legs 10-222 A/8, special hook 10-222A/2 and adapter 10-222 A/3.
^ Take weight of engine/transmission assembly on spindles.
^ Turn wheels fully onto left lock.
^ Raise vehicle.





^ Remove sound insulation tray -arrows-.





^ Remove left sound insulation -arrows-.
^ Remove right sound insulation.
^ Disconnect drive shafts from flanged shafts and tie up as high as possible. When tying up shafts do not damage body surface protection.





^ Disconnect front exhaust manifold -A-.





^ Remove supports -arrows- and unhook support elements.
^ Secure front exhaust pipe to body work, around area of catalytic converter, with wire.





^ Remove pendulum support (arrows -A- and -B-).
^ Remove power steering pipe from starter and transmission.
^ Remove starter.





^ Unbolt engine side of assembly mounting from engine carrier from above -arrows-.





^ Remove left assembly mounting -2- hex bolts -arrows- from left mount -1-.
^ Carefully tilt engine and transmission by lowering left-hand spindle approximately 60 mm on support bar 10-222A





^ Remove left mount -1- from transmission -arrows-.





^ Pull off gate selector cable -A- with relay lever in direction of arrow.
^ Tie up selector cable with transmission selector lever and gate selector cable with relay lever.
^ Incline engine/transmission assembly further by lowering it via left spindle of support bar 10-222A.





^ Bolt support rail T10036 to both pendulum support securing holes on subframe (bolts -A-).
^ Fit support 3300 A so that it is almost touching assembly mounting and secure (arrows).
^ Press engine/transmission forward carefully.

Note: Do not damage any of the connecting pipes and hoses when moving engine/transmission assembly.

^ Remove lower rear engine/transmission securing bolts (arrow -A-).
^ Remove lower engine/transmission securing bolts.

^ Set up transmission support 3282 with adjustment plate 3282/27 to remove transmission 02M.
^ Align arms of transmission support according to holes in adjustment plate.





^ Bolt support elements -A-, as illustrated, on adjustment plate.





^ Place transmission jack under vehicle. Arrow symbol -B- (Illustration N34-1052) on adjustment plate points to front of vehicle.
^ Align adjustment plate parallel to transmission.
^ Secure transmission to transmission support 3282 with bolt -A-.
^ Remove engine/transmission connecting bolt (arrow).
^ Press transmission off dowel sleeves and carefully swing toward subframe.
^ Lower transmission slightly and incline to left via spindles of transmission support 3282.
^ Lower transmission carefully, guiding right-hand flange shaft in area of flywheel and left-hand flange shaft in area of subframe.
^ When lowering the transmission change position of transmission using transmission support 3282 spindles.

Note: Do not damage power steering pipe when lowering transmission.

Installing
^ Clean input shaft splines and lightly grease with GOOD 100 grease.
The clutch plate must be able to slide lightly back and forth on the input shaft.
^ Check whether dowel sleeves for aligning engine/transmission are installed in cylinder block and install if necessary.
^ Ensure that intermediate plate is correctly positioned on engine.





^ Bolt support rail T10036 to both pendulum support securing holes on subframe (arrows).
^ Install support 3300 A so that it is almost touching assembly mounting and secure (arrows).
^ Press engine forward carefully.

Note: Do not damage power steering pipe.

Set up transmission support 3282 with adjustment plate 3282/27 to install transmission 02M.
^ Align arms of transmission support according to holes in adjustment plate.





^ Bolt support elements -A-, as illustrated, on adjustment plate.
^ Place transmission on transmission jack.
^ Align adjustment plate and transmission parallel with one another.





^ Place transmission jack under vehicle. Arrow symbol -B- (= Fig. N34 1052) on adjustment plate points to front of vehicle.
^ Secure transmission to transmission support 3282 with bolt -A-.
^ Incline transmission to left via spindles of transmission mounting 3282.
^ Install transmission.

Note: Do not damage power steering pipe.

^ Install lower engine/transmission connecting bolt (arrow -A-).
^ Install lower engine/transmission securing bolts.





^ Remove pressing device 3300 A (arrows).
^ Remove bolts -A- and remove support rail T10036.





^ Install gate selector cable -A- with relay lever in direction of arrow.





^ Install left mount -1- on transmission -arrows-.
^ Align engine/transmission in installation position.





^ Install new hex bolts (arrows) for left assembly mounting -2- in mount -1-.





^ Install new hex bolts (arrows) for right assembly mounting in engine mounting.

WARNING! Do not remove support bar 10-222A until the bolts securing the left and right assembly mountings have been tightened to torque setting.





^ Install pendulum support (arrows -A- and -B-).
^ Use new bolts for securing.
^ Install drive shafts to transmission.
^ Reconnect exhaust system.
^ Install starter and secure with lower bolt.
^ Install retainer for power steering pipe on starter and on transmission.
^ Install upper engine/transmission securing bolts.





^ Install Ground strap at upper engine/transmission securing bolt. Z -





^ Attach connector to speedometer sender (arrow).





^ Push pipe/hose in direction of arrow and press down clamp (arrow).
^ Remove special tool 3094.
^ Install upper securing bolt on starter.





^ Install cable retainer -A- on starter (arrow 3).
^ Attach connectors for starter (arrow -1-) and back-up light (arrow -2-).





^ Install cable support bracket on transmission (arrows).





^ Install gear selector cable -B- with transmission selector lever (arrow -2-)
^ Secure gate selector cable -A- with relay lever using lock washer (arrow -1-).
^ Install power steering pipe (arrow -3-).
^ Install battery carrier.





^ Install complete air cleaner housing by tightening bolts -4- and -5-.
^ Install intake hose -1-.
^ Attach connector -2- and hose -3- to Mass Air Flow sensor.
^ Install battery.
^ Reconnect Ground strap to battery.

Note: Note radio coding for vehicles with coded radio.

^ Check transmission oil.
^ Specifications, Refer to Manual Transmission/Transaxle, Specifications, Mechanical.
^ Bleed clutch system.
^ Adjust gear selector mechanism.
^ Install engine cover.
^ Install insulation tray below engine/transmission, if so equipped.





Tightening torques





Transmission to engine
1) Also starter to transmission
2) Always replace bolts
Items A + B = Dowel sleeves





^ Transmission mount -1- to transmission
^ Replace bolts
Bolts -arrows- 50 Nm + 90°





^ Transmission to body
Bolts -arrows- 100 Nm





^ Rear transmission mounting
^ Replace bolts
Bolts -A- 20 Nm + 90°
Bolts -B- 40 Nm + 90°

Note: Install engine/transmission mountings stress-free.

Selector cable support bracket to transmission 25 Nm
Transmission selector lever to transmission 25 Nm
Hydraulic pipe to transmission 25 Nm