Transmission, Removing and Installing

Special tools, testers and auxiliary items
^ Transmission jack V.A.G 1383 A
^ Transmission support 3282
^ Adjustment plate 3282/10
^ Assembling appliance 3139
^ Wrench set for Oxygen sensors 3337
^ Grease G 000100

Removing

Note: In a later step, the battery Ground (GND) strap must be disconnected. Therefore check whether a coded radio is installed. If necessary, obtain the anti-theft coding.

- With ignition switched off disconnect battery Ground strap.





- Remove intake hose -A- (arrows).
- Unbolt coolant system expansion tank -B- (arrows) and lay to one side.
- Unscrew lambda probes on left and right exhaust pipes with special tool 3337 and move clear to the side.
- Unscrew engine/transmission securing bolts accessible from above.





- Remove noise insulation -arrows-.





- Unbolt bracket for noise insulation -arrow-.





- Detach heat shields -arrow 1- and -arrow 2- above right-hand axle shaft.
- Remove heat shield above left axle shaft.





- Unbolt front exhaust pipes with catalytic converters from left and right exhaust manifolds (3 nuts on each side) -arrows-.
- Remove clamping sleeves of exhaust system and remove catalytic converters together with exhaust pipe downward.





- Remove engine speed sender -G28- on left of transmission -arrow- and move clear to the side.
- Remove drive axles from the drive flanges and tie up as high as possible; do not damage the protective coating.





- Pull connector off road speed sender (arrow -A-).
- Pull off reversing light connector (arrow -B-). Disconnect all other electrical connections and Ground wires from transmission and from the engine/transmission securing bolts.





- Unbolt starter from engine/transmission and secure as necessary.

Notes: Starter cables do not have to be disconnected.





- Detach selector rod arrow -A-.
- Unscrew hexagon socket head bolt out of push rod -arrow B-.

Note: Illustration shows manual transmission 012.





- Unbolt heat shield for driveshaft from Torsen differential cover-arrows-.





- Unbolt driveshaft -1- from transmission and rest it on heat shield -2-.
- Secure driveshaft to fuel pipe bracket -3- with wire -arrow-.





- Unscrew bottom engine/transmission securing bolts, except for bolts indicated by arrows -A- and -B-.





- Set up transmission support 3282 for removing manual transmission 01A (all wheel drive) with adjustment plate 3282/10 and attach to transmission jack V.A.G 1383 A.
A - Attachments

Notes:
^ Attachments -A- are shown in schematic form; arrow -B- points in the direction of travel.
^ Adjustment plate 3282/10 only fits in one position.





- Run transmission jack V.A.G 1383 A with transmission support 3282 in under the transmission and take up the weight of the transmission.

Note: If the transmission lift 3282 is not available, the transmission can be removed and installed using transmission lift 1333A and universal mounts VAG135912.





- Align adjustment plate parallel to transmission and lock safety support (arrow) on transmission.





- Unbolt right and left transmission supports complete with bonded rubber mountings from transmission and subframe -1- and -2-.





- Remove remaining engine/transmission securing bolts (arrows -A- and -B-).
- Press transmission off dowel sleeves and lower carefully with transmission jack V.A.G 1383 A just far enough for access to the slave cylinder.

Note: When lowering transmission ensure hydraulic pipe/hose to slave cylinder is not damaged.





- Remove clutch slave cylinder (arrow) and secure with wire, do not disconnect pipe.

Note: Do not depress clutch pedal after removing slave cylinder.

- Lower transmission completely.

Note: When lowering transmission ensure there is sufficient clearance to axle shafts.

Securing transmission to repair stand
Required special tools and equipment





^ Holding plate VW 309





^ Transmission support VW 353





- Secure transmission to assembly stand when performing assembly work using transmission support VW353 and holding plate VW309.

Transporting the transmission
2024 A engine sling in connection with 10222 A engine support bridge can be used to transport the transmission.





- Bolt in two tabs of 2024A engine sling with bolts -A- M10 x 50.
- Hook in 2024A engine sling and lift shop crane slightly.
- The rails are to be hooked into the 4th hole in position 3 and position 6 of 2024A engine sling.

CAUTION: Use securing pins at hooks and pins.

Installing
Installation is carried out in the reverse order, when doing this note the following:
- Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease G 000 100 to the splines. Do not grease guide sleeve.
- Check clutch release bearing for wear, replace if necessary.
- Coat contact surface of clutch slave cylinder push rod with a thin layer of copper grease, e.g. Z 381 351 TE.
- Check whether dowel sleeves for aligning engine/transmission are fitted in cylinder block, install if necessary.
- The threaded holes for mounting the clutch slave cylinder to the transmission and for the shift coupling to the shift rod must always be cleaned using of residual locking fluid a threaded tap before assembly.
- Always replace all self-locking nuts.





- Lift transmission until clutch slave cylinder with bracket for pipe/hose can be installed (arrow).
- Fit intermediate plate between transmission and engine onto engine dowel sleeves.
- Ensure that the intermediate plate is correctly positioned on engine.
- Install lower engine/transmission securing bolts and bolts for starter when doing this install starter.
- Before installing, use a tap to clean threads in drive flange for driveshaft on transmission to remove traces of locking compound.
- Replace gaskets on axle shafts and on front of driveshaft.
- Bolt on driveshaft.
- Align exhaust system so it is free of stress
- Insert oxygen sensors and tighten.
- If equipped, install the engine speed sensor G28-.
- Check adjustment of shift and pivot rod and adjust, if necessary.
- Check oil level in transmission.
- After connecting battery, enter anti-theft code for radio.
- Close electric windows in front doors all the way to their top positions using electric switches.
- Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic one-touch function.
- Set clock to correct time.





Tightening torques Part 1 of 6





Tightening torques Part 2 of 6





Tightening torques Part 3 of 6





Tightening torques Part 4 of 6





Tightening torques Part 5 of 6





Tightening torques Part 6 of 6