Volkswagen Golf Variant / Jetta. Manual - part 250

 

  Index      Volkswagen     Volkswagen Golf Variant (2007), Jetta (2005) - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  248  249  250  251   ..

 

 

Volkswagen Golf Variant / Jetta. Manual - part 250

 

 

diaphragm -arrow 1- at the top of the transmission support (grad‐

ual introduction).
– Loosen the bolts -A- that connect the transmission mount to

the engine.

– Remove the transmission mount bolts -B- on the bevel gear.
Continuation for All

– Remove the subframe mount bolts -arrows- on the transmis‐

sion.

– Adjuster the spindles on the Engine Support Bridge - 10-222A-

and lower the transmission to dimension -a-.

• Dimension -a- = approximately 60 mm

Note

When moving the engine/transmission assembly, be aware of the

coolant hoses between the engine and heater core; do not strain.

– Remove the bracket from the transmission -arrows-.

5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehicles with

AWD    

175

then remove the relay lever.

Plastic Relay Lever
– Remove the relay lever with the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89

 .

Continuation for All
– Remove the gearshift lever from the gearshift shaft.

– Remove the lower transmission/engine connecting bolts

-1 and 2- (engine side).

Note

Loosen the engine/transmission connecting bolt -3- and leave it

in so that it is hand-tight.

Align the Transmission Support - 3282- with the Transmission

Support - Mounting Plate 33 - 3282/33- in order to remove the

“02Q AWD” transmission.
– Insert the Transmission Support - 3282- into the Engine and

Gearbox Jack - VAS6931- .

– Align the arms of the Transmission Support - 3282- so that

they match up with the holes in the Adjustment Plate .

– Install the Support Elements -A- as illustrated on the Adjust‐

ment Plate .

– Install the Transmission Support - Pins 29 - 3282/29- in place

of the Mounting Element -C-.

– Position the Engine-Gearbox Jack - VAG1383A- under the

vehicle. The arrow symbol -B- on the Adjusting Plate points in

direction of travel.

– Align the Adjustment Plate so that it is parallel to the trans‐

mission.

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

hole on the transmission for the pendulum support bolt.

– Secure the Slide Hammer Set - Adapter 40 - VW771/40- inside

the threaded hole in the transmission housing as shown.

– Secure the transmission on the Transmission Support - 3282-

with an M10 x 20 bolt -A-.

176

Vehicles with A Particulate Filter
– Remove the transmission support -A- from the bevel box -C-.
Continuation for All
– Move the transmission near the differential/bevel box slightly

towards the rear, so that the small cover plate -B- or the inter‐

mediate plate is not damaged.

– Then guide the transmission past the flywheel -arrow-.

– Then turn the transmission using the spindles -1- and -2- for

the Transmission Support - 3282- so that it is does not touch

the longitudinal member.

– Carefully lower the transmission.

Note

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

5. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehicles with

AWD    

177

Transmission, Installing

Note

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

tools needed. Refer to

⇒ “5.1 Transmission, TDI, Removing and Installing”,

page 166

 .

Replace the self-locking nuts and bolts.

Replace bolts that were tightened with an additional turn.

Install any cable ties that were loosened or cut off during re‐

moval at their same location.

Clean input shaft splines and (on used clutch plates) the hub

splines, remove corrosion and apply a very thin coating of

Grease for Clutch Disc Shaft Splines - G 000 100- to the

splines. Then move the clutch plate back and forth on the input

shaft until the hub moves freely on the shaft. Excess grease

must be removed.

– If the transmission is replaced, transfer the transmission shift

lever and the relay lever.

– Clean any locking compound residue from all threaded holes

using a tap.

– Check whether there are centering sleeves for the engine/

transmission in the cylinder block; install if necessary.

If the alignment sleeves are missing, it will be difficult to shift, there

will be clutch problems and the transmission may make noises

(loose rattling).
– Make sure the intermediate plate is engaged on the sealing

flange and pushed onto the alignment sleeves -arrows-.

– Check the release bearing for wear. Replace the clutch slave

cylinder with release bearing if necessary. Refer to

⇒ “2.2 Clutch Slave Cylinder with Release Bearing, Removing

and Installing”, page 52

 .

178

 

 

 

 

 

 

 

Content   ..  248  249  250  251   ..