Volkswagen Golf Variant / Jetta. Manual - part 578

 

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Volkswagen Golf Variant / Jetta. Manual - part 578

 

 

Tensioning Strap - T10038- .

– Remove the right flange shaft bolt at the transmission using

the Socket And Extended Bit - T10107A- . Insert two bolts in

the flange and counterhold with a tire iron.

The bolt has 6 mm inner hex. The bolt can also be removed and

installed using the Long Hex Socket - VAG1669- .
– Remove the flange shaft.
– Seal the flange shaft opening with a suitable plug.
Continuation for All Vehicles

– Remove the exhaust system bracket from the subframe.

– Remove the front exhaust pipe so that the lower bolts

Pipes/Mufflers .

– Remove the engine cover from the cylinder head.
– If there are hose and cable connections located near the en‐

gine lifting eyes for the Engine Support Bridge - 10-222A- ,

these must now be removed.

4. Transmission, Removing and Installing, Jetta from MY 2005, Golf Wagon from MY 2007 and Golf Wagon from MY 2010    

133

Bridge - 10-222A- but do not lift.

Remove all bolts -1 and 2- from the transmission bracket.
– Then lower the engine/transmission slightly using the Engine

Support Bridge - 10-222A- spindle so that the transmission

bracket can be removed.

A maximum of 5 turns are enough to remove the transmission

bracket.
In many cases it is not necessary to lower the spindles when re‐

moving the transmission later.

To remove the transmission 0AM, the Transmission Support -

3282- is equipped with the Transmission Support - Mounting Plate

59 - 3282/59- and positioned on the Engine and Gearbox Jack -

VAS6931- .
– Align the arms of the Transmission Support so that they match

up with the holes in the Transmission Support - Mounting Plate

59 - 3282/59- .

– Install the mounting elements as illustrated on the Transmis‐

sion Support - Mounting Plate 59 - 3282/59- .

– Place the Engine and Gearbox Jack - VAS6931- under the

vehicle.

• The arrow symbol on the Transmission Support - Mounting

Plate 59 - 3282/59- points in the direction of travel.

– Align the Transmission Support - 3282- so that it is parallel to

the transmission.

– Transmission Support - Pins 29 - 3282/29- are inserted in the

»rear« hole for the pendulum support.

134

as shown. While doing this, place the drift plate under the

transmission housing and not under the Mechatronic.

– Secure the transmission with a Tensioning Strap - T10038- .
– Support the transmission by lifting it from underneath using the

Engine and Gearbox Jack - VAS6931- .

The transmission is disconnected from the engine in this position.
– Remove the remaining engine/transmission connecting bolts.
– Remove transmission from engine »while being careful of se‐

lector lever cable« and lower transmission.

Note

The distance between the engine flange and transmission

flange should be approximately 50 mm before lowering the

transmission.

Pay attention to all lines and coolant hoses when lowering the

transmission.

Note

Always replace the needle bearing -arrow- after separating the

engine and transmission.

If the needle bearing in the crankshaft is damaged, the gears

will no longer shift correctly.

Gr.  13 ; Crankshaft; Needle Bearing in Crankshaft, Replacing .

Transport the Transmission and Secure to the Assembly Stand.

Refer to

⇒ “6 Transmission, Transporting and Securing To Assembly

Stand”, page 191

 .

Install the transmission. Refer to

⇒ “4.6 Transmission, Installing, Jetta from MY 2005, Golf Wagon

from MY 2007, Golf Wagon from MY 2010”, page 157

 .

If the Transmission is Going to be Shipped:

The bracket is located on the front of the transmission in some

cases.
– Remove the bracket if a »new« transmission is being installed,

because brackets are not equipped on »new« transmissions.

– Install the right flange shaft on a transmission with flange

shafts. Refer to

⇒ “1.4 Right Flange Shaft Seal, Replacing”, page 210

 .

4.3

Transmission, Removing, Vehicles with

1.6L/75 kW MPI Engine

Special tools and workshop equipment required

4. Transmission, Removing and Installing, Jetta from MY 2005, Golf Wagon from MY 2007 and Golf Wagon from MY 2010    

135

♦ Tensioning Strap - T10038-
♦ Engine Support Bridge - Gearbox Bracket - T10346-
♦ Engine and Gearbox Jack - VAS6931-
Brief Description
The transmission is removed downward by itself without the en‐

gine.
The battery, the air filter and the starter are removed »from

above«.
The noise insulation under the engine/transmission, the lower

cover in the left front wheel housing and the pendulum support

are removed »from below«.
Removing
– Lift the vehicle, all four take-up points of lifting platform at the

same height.

Filter; Overview - Air Filter Housing .

– Remove the battery and the battery tray. Refer to ⇒  Electrical

Equipment; Rep. Gr.  27 ; Battery; Battery, Removing and In‐

stalling .

27 ; Starter; Starter, Removing and Installing .

– Remove the lock washer in the direction of the -arrow-.
Always replace the circlip on the selector lever cable.

136

 

 

 

 

 

 

 

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