Transmission, Removing and Installing

Transmission, removing and installing, 02J, 5 Spd. M/T

Special tools and equipment:

- VW 457/1 Support rails
- 10-222 A Support device
- 10-222 A/8 Engine support feet
- 3282 Transmission support
- 3282/8 Adjustment plate
- 3300 A Engine support

Special tools and equipment:

- 3336 Transmission supporting jig.
- VAG 1331 Torque wrench
- VAG 1332 Torque wrench
- VAG 1383 A Engine/transmission jack
- VAS 5024 Installing pliers

Modifying support rails VW 457/1

- To secure support rail VW 457/1 to the subframe a new hole is required.
- Dimensions given are in mm.
- Drill a 8.5 mm diameter hole (arrow) in support rail VW 457/1.

Modifying guide 10-222 A/21 from support device 10-222 A
Support device10-222A is required to support the engine/transmission.

A new hole is required to secure the adapter 10-222 A/8 to the guide 10-222 A/21.
Dimensions given are in mm.
- Drill a hole of 12.5 mm diameter (arrow) in guide 10-222 A/21.

Removing
- Remove cover from engine.
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery ground (GND) strap.
- Remove power steering reservoir from battery carrier; do not open/loosen hoses.
- Tie reservoir to lock carrier.
- Install battery.
- Remove battery carrier.

- Pull intake hose -1- and connector -2- off Mass air flow sensor.
- Remove bolts -3-, -4- and -5-.
- Remove air cleaner complete.

Vehicles up to 05.99

- Pull connector off vehicle speed sensor (arrow -1-).
- Pull off reverse light connector (arrow -2-).

- Remove balance weight -A- and gear selector cable -B- from gear selector lever.
- Remove selector cable with washer and four-sided nut.
- Pull gate selector cable off actuating arm/relay lever -C- by lifting lug in direction of (arrow).

- Remove cable support bracket from transmission (arrows), if necessary unclip hose at cable support bracket first.

Vehicles as of 06.99

- Remove cable support bracket from transmission (arrows), if necessary unclip hose -A- at cable support bracket first.

- Pull off gate selector cable -A- with relay lever, remove circlip (arrow) to do this.
- Remove gear selector cable -B- with transmission selector lever, remove nut (arrow) to do this.
- Tie selector cable with transmission selector lever and gate selector cable with relay lever up.

- Pull connector off road speed sensor (arrow -1-).
- Pull off reverse light connector (arrow -2-).

Continued for all vehicles

- Remove slave cylinder -arrows-, place to side and secure with wire, do not disconnect pipes.

Note: Do not depress clutch pedal.

- Remove cable retainer (arrow -1-) on starter.
- Remove upper securing bolt (arrow -2-) on starter.
- Remove ground (GND) strap at engine/transmission upper securing bolt.
- Remove upper engine/transmission securing bolts.
- If there are hoses and cable connections in area of engine mounting eye for support 10-222A, remove these now.

- Erect support device 10-222 A with adapters10-222 A/8.

Note: Do not seat the adapters 10-222 A/8 on the securing bolts for the front end/fender.

- Take weight of engine/transmission assembly on spindles.
- Remove noise insulation tray.

- Remove left noise insulation -arrows-.
- Remove power steering line from starter and transmission.
- Remove starter.
- Remove right hand inner constant velocity joint protective cover from engine if installed.
- Turn wheels fully onto left lock.
- Disconnect drive shafts from flanged shafts and tie up as high as possible, when doing this do not damage surface protection.

- Remove flywheel small cover plate -A- behind right-hand flanged shaft (arrows), if installed.
- Disconnect exhaust system after front exhaust line at double clamp -A-. Remove front exhaust line supports from subframe if necessary.

- Remove pendulum support (arrows -A- and -B-).

- Remove transmission support (arrow -A-) from transmission.
- Remove hex bolts (arrows -B-) from left-hand hand assembly mounting.
- Incline engine/transmission assembly by lowering it via left spindle of support bar 10-222A.
- Transmission mount -A- securing bolts (arrows) must be accessible.

- Remove transmission mount -A- (arrows).
- Remove additional fan on right-hand side of vehicle if installed.

- Bolt support rail VW 457/1 to both pendulum support securing holes on subframe.
- Spacers totaling 6 mm must be inserted between subframe and support rail VW 457/1.
-A- Qty. 2 hex bolts M 8 x 25

Note: Mounting rail T10036 can be used instead of mounting rail VW 457/1.

- Install support 3300 A and secure (arrows).

Vehicles with a 1.8L engine
Remove a lower engine/transmission securing bolt so that support 3300 A can be installed.

Note: The support 3300 A must be installed directly next to the transmission on the engine.

Continued for all vehicles
- Press engine and transmission forward carefully.

Note: Do not damage power steering. line when moving engine and transmission assembly.

- Assemble transmission jack with transmission support 3282, adjustment plate 3282/8 for "02A" transmission and support elements as follows:
- Place adjustment plate 3282/8 on transmission support 3282. (Adjustment plate only installs in one position).
- Align arms of transmission support according to holes in adjustment plate.

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

- Position transmission jack under vehicle, arrow symbol -B- (illustration V34-2670) on alignment plate faces toward front of vehicle.
- Align adjustment plate parallel to transmission and lock safety supports on transmission.
- Remove lower engine/transmission securing bolts.

- Press transmission off dowels and carefully swing toward sub-frame.

- Lower transmission carefully; when doing this guide right-hand flange shaft -A- in area of flywheel as illustrated and guide left-hand flange shaft -B- in area of subframe.
- When lowering transmission change position of transmission using transmission support 3282 spindles.

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

Transporting the transmission

- Bolt transmission lifting device 3336 to clutch housing.

- Set support arm on sliding piece with locking pin (arrow).
- No. of holes visible = 5
- Lift transmission with workshop crane and transmission lifting device 3336.
- Place transmission, for example onto transport container.

Installing

Note: Before installing transmission press clutch release lever toward transmission housing and secure with assembly pin, assembly bolt or M8 x 35 bolt. Remove after transmission has been installed. The hole will then be sealed by the 3rd cable support bracket securing bolt or plugged.

Note: When replacing transmission, the sensors for speedometer (Fig.), gear selector and relay lever must be transferred to new assembly.

- Clean input shaft splines and lightly grease with G000 100 grease.
- Clutch plate must be able to slide lightly back and forth on input shaft.
- Check whether dowel sleeves for aligning engine and transmission are installed in cylinder block, install if necessary.
- Make sure that intermediate plate is correctly positioned on engine.

- Bolt support rail VW 457/1 to both pendulum support securing holes on subframe.
- Spacers totaling 6 mm must be inserted between subframe and support rail VW 457/1.
- -A- Qty. 2 hex bolts M8 x 25

Note: Mounting rail T10036 can be used instead of mounting rail VW 457/1.

- Install support 3300 A and secure (arrows).

Vehicles with 1.8l engine
The support 3300 A must sit on the threaded boss on the engine.

Continued for all vehicles
- Press engine forward carefully.

Note: Do not damage power steering line.

- Assemble transmission jack with transmission support 3282, adjustment plate 3282/8 for "02A" transmission and support elements as follows:
- Place adjustment plate 3282/8 on transmission support 3282. (Adjustment plate only installs in one position).
- Align arms of transmission support according to holes in adjustment plate.

- Install mounting element -A-, as illustrated on alignment plate.
- Install transmission on transmission jack.
- Align adjustment plate and transmission parallel with one another and lock safety supports on transmission.

- Position transmission jack under vehicle, arrow symbol -B- (illustration V34-2670) on alignment plate faces toward front of vehicle.
- Align transmission to engine.

Note: Do not damage power steering line.

- Install lower engine and transmission securing bolts.

- Remove support 3300 A (arrows).
- Remove bolts -A- and remove support rail VW 457/1.
- Install upper engine and transmission securing bolts.

- Install transmission console -A- with new bolts (arrows).
- Align engine and transmission in installation position.

- Install new hex bolts (arrows -B-) for left hand assembly mounting in transmission mounting.
- Install transmission support (arrows -A-) to transmission.

WARNING: Do not remove support bar 10-222A until the bolts securing the left-hand transmission mount have been tightened to torque setting.

- Install lower engine and transmission securing bolt (arrow -A-).
- Install pendulum support (arrows).
- Use new bolts for securing.
- Reconnect exhaust system.
- Install retainer for power-assist steering line on starter and on transmission.

- If it was removed install small cover plate -A- behind right-hand drive flange (arrows).
- Install drive shafts to transmission.
- If it was removed install protective cap for right-hand inner constant velocity joint to engine.
- Install starter.

- Install slave cylinder

Vehicles up to 05.99

- Install cable support bracket on transmission (arrows), if necessary push hose onto cable support bracket.

- Install gear selector cable -B- and balance weight -A- on gear selector lever.
- Install gate selector cable on follower/relay lever -C- to do this lift lug in direction of arrow.

Vehicles as of 06.99

- Install cable support bracket to transmission -arrows-, press hose -A- on to cable support bracket.
- Install gear selector cable -B- with transmission selector lever (arrow).
- Install gate selector cable -A- with relay lever and secure (arrow).

Continued for all vehicles

- Attach back-up light connector (arrow -2-). Attach all other electrical connections and ground wires to transmission and to engine and transmission securing bolts.
- Attach connector to speedometer sensor (arrow 1).
- Adjust gear change mechanism.
- Assemble air intake duct
- Install battery carrier.
- Install battery.
- Reconnect ground (GMD) strap to battery.

Note: Note radio coding for vehicles with coded radio.

- Install power steering reservoir on to battery carrier.
- Check transmission oil.
- Install engine cover.
- Install noise insulation tray.

Tightening torques