Volkswagen Golf Variant / Jetta. Manual - part 158

 

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Volkswagen Golf Variant / Jetta. Manual - part 158

 

 

the connector -arrow- from the Transmission Neutral Position

Sensor - G701- .

27 ; Starter .

Align the Transmission Support - 3282- with the Transmission

Support - Mounting Plate 39 - 3282/39- in order to remove the

“0A4” transmission.
– Insert the Transmission Support - 3282- into the Engine and

Gearbox Jack - VAS6931- .

– Align the arms of the Transmission Support so that they match

up with the holes in the Adjustment Plate .

– Install the Mounting Elements -A and C-, on the Adjusting

Plate , as illustrated.

– Position the Engine and Transmission Jack under the vehicle.

The arrow symbol -B- on the Adjusting Plate points in the di‐

rection of travel.

– Align the Adjusting Plate so that it is parallel to the transmis‐

sion and secure the safety support to the transmission.

– Install the Transmission Support - Pins 29 - 3282/29- into the

hole for the pendulum support bolt on the transmission.

– Remove the lower engine/transmission bolts.

– Remove the transmission from the alignment bushings and

carefully move it toward the subframe.

– Rotate the transmission near the differential downward.
– Push the engine forward slightly with a second technician.

94

-A- into flywheel/intermediate plate area as shown.

– Use spindles on the Transmission Support - 3282- to adjust

the position of the transmission while lowering it.

Note

Pay attention to all of the lines when lowering the transmission.

2.2

Transmission, Installing

⇒ “2.2.1 Tightening Specifications”, page 101

Note

Refer to “Transmission, Removing” to get a list of the special tools

needed. Refer to

⇒ “2 Transmission, Removing and Installing, Jetta from MY 2005,

Golf Wagon from MY 2007, , Golf Wagon from MY 2008”,

page 88

 .

Pay attention to the following list for the subject -“Transmission

Fluid, Checking and Filling”.

“Transmission Fluid, Checking and Filling”

 

 

»No«

»Yes«

»Yes«

Transmission

Original Part

X

 

 

no oil outlet

X

 

Was completely dis‐

assembled

X

before installation

-item 3-

⇒ Item 3 (page 184)

transmission fluid

capacity. Refer to

⇒ “2.3 Codes, Trans‐

mission Allocation

and Capacities”,

page 3

 

Was partially disas‐

sembled

• (the transmission

housing and the

clutch housing

were not separa‐

ted from each

other)

 

 

X

after installation. Re‐

fer to

⇒ “6 Transmission

Fluid, Checking and

Filling”, page 157

 .

– Clean any locking compound residue from all threaded holes

using a tap.

– Always replace self-locking bolts and nuts.
– Make sure the alignment sleeves for centering the engine/

transmission are installed inside the cylinder block. Install

them if necessary.

2. Transmission, Removing and Installing, Jetta from MY 2005, Golf Wagon from MY 2007, , Golf Wagon from MY 2008    

95

will be clutch problems and the transmission may make noises

(loose rattling).
– Make sure the intermediate plate fits correctly on the engine.
– Clean the driveshaft splines and grease lightly with Grease For

Clutch Disc Shaft Splines - G 000 100- .

It must be possible to slide the clutch plate back and forth on the

input shaft.
Align the Transmission Support - 3282- with the Transmission

Support - Mounting Plate 39 - 3282/39- in order to install the “0A4”

transmission.
– Align the arms of the Transmission Support so that they match

up with the holes in the Adjustment Plate .

– Install the Mounting Elements -A and C- ( Transmission Sup‐

port - Pins 29 - 3282/29- ) on the Adjusting Plate as illustrated.

– Place the transmission on the Engine and Gearbox Jack .
– Align the Adjustment Plate so that it is parallel to the trans‐

mission.

– Install the Transmission Support - Mounting Plate 29 -

3282/29- into the hole in the transmission for the pendulum

support bolt.

– Position the Engine and Gearbox Jack under the vehicle. The

-arrow symbol B- on the adjusting plate points in direction of

travel.

– Using the spindles of the Transmission Support - 3282- , screw

the transmission downward in the area of the differential.

– Push the engine forward slightly with a second technician.

– Then carefully lift transmission, when doing so, guide the right

flange shaft -A- in the area of the flywheel/intermediate plate

as shown.

– Using the spindles of the Transmission Support - 3282- , screw

the transmission upward in the area of the differential.

– Lift the transmission to engine.
• A second technician must continue to press the engine for‐

ward.

– Align the transmission with the engine and install it.
– Install the lower bolts for attaching the engine to the transmis‐

sion and tighten them to the tightening specification. Refer to

⇒ “2.2.1 Tightening Specifications”, page 101

 .

– After the transmission is attached to the engine, remove the

Engine and Gearbox Jack from the transmission.

96

-A- -arrows-.

– Install the upper engine/transmission connecting bolts and

tighten to the tightening specification. Refer to

⇒ “2.2.1 Tightening Specifications”, page 101

 .

– Attach the bracket -A- with the new bolts to the transmission

-arrows- and tighten them to the tightening specification. Refer

to 

⇒ “4.1 Overview - Subframe Mount”, page 154

 .

– Align the engine/transmission in its installed position. Lift until

the transmission bracket is touching the transmission mount

completely.

Caution

There is a risk of damaging the threads in transmission bracket

by inserting bolts at an angle.

♦ Before installing bolts -arrows-, transmission bracket and

transmission mount support arm must be absolutely par‐

allel to each other. If necessary, lift the back of the trans‐

mission using the Engine and Gearbox Jack .

Note

Install the engine/transmission mount free of tension. Refer to ⇒ 

Rep. Gr.  10 ; Engine, Removing and Installing .

– Install new bolts -arrows- of left assembly mounting into trans‐

mission mount and tighten to tightening specification. Refer to

⇒ “4.1 Overview - Subframe Mount”, page 154

 .

WARNING

Only remove Engine Support Bridge - 10 - 222 A- when the left

and right subframe mount bolts are tightened to the tightening

specification.

2. Transmission, Removing and Installing, Jetta from MY 2005, Golf Wagon from MY 2007, , Golf Wagon from MY 2008    

97

 

 

 

 

 

 

 

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