Transmission, Removing and Installing

Transmission, removing and installing, 02M, 5 and 6 Spd. M/T

Special tools and equipment:

- 10-222 A Support
- 10-222 A/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 and 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 line (arrow -3-).





- Pull connector off speedometer sensor (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 3094 hose clamp.
- Pull out clamp (arrow) and line/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.





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





- Remove sound insulation tray (arrows).





- Remove left sound insulation (arrows).
- Remove right sound insulation.





- Disconnect axle 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 bodywork, 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 side spindle approximately 60 mm on support bar 10-222 A.





- 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 lines 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, onto adjustment plate.





- Place transmission jack under vehicle. Arrow symbol -B- (go to 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 side flanged shaft in area of flywheel and left side flanged shaft in area of subframe.
- When lowering the 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 beam on sliding piece with locking pin (arrow).
- No. of holes visible = 6
- Take transmission out with workshop crane and transmission lifting device 3336.
- Lower transmission.

Installing
- Clean input shaft splines and lightly grease with G 000 100 grease.
- Clutch plate must be able to slide lightly back and forth on 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 line.

- 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, onto adjustment plate.
- Place transmission on transmission jack.
- Align adjustment plate and transmission parallel with one another.





- Place transmission jack under vehicle. Arrow symbol -B- (go to 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 line.

- 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 installed 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.





- Use new bolts and install pendulum support (arrows -A- and -B-):
- Install axle shafts to transmission:
- Reconnect exhaust system:
- Install starter and secure with lower bolt.
- Install retainer for power steering line on starter and on transmission.
- Install upper engine/transmission securing bolts.
- Tighten upper engine/transmission securing bolts to prescribed torque





- Install ground strap at upper engine/transmission securing bolt.





- Attach connector to speedometer sensor (arrow).





- Push line/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-).

Note: For all repairs on the starter:





- Install selector cable support bracket on transmission (arrows) and tighten bolts to prescribed torque.





- Install gear selector cable -B- with transmission selector lever (arrow -2-).
- Tighten hex nut (arrow -2-) to prescribed torque.
- Secure gate selector cable -A- with relay lever using lock washer (arrow -1-).
- Install power steering line (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.
- 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








Transmission to body








Rear transmission mounting
Replace bolts





Note: Install engine/transmission mountings stress-free: