Volkswagen Golf Variant / Jetta. Manual - part 582

 

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Volkswagen Golf Variant / Jetta. Manual - part 582

 

 

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.

– Mount both remaining mounting elements on the transmission

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.

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

149

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

 .

4.5

Transmission, Removing, Vehicles with

1.6L/77 kW TDI CR Engine

Special tools and workshop equipment required
♦ Engine Support Bridge - 10-222A-
♦ Engine Support Bridge - Engine Support 3 - 10-222A/3-
♦ Engine Support Bridge - Engine Support 18 - 10-222A/18-
♦ Transmission Support - Mounting Plate 59 - 3282/59-
♦ Multipoint Socket - T10035-
♦ Socket - Xzn 14 - T10061-
♦ Transmission Support - 3282-
♦ Insert Tool - 18mm - T10179-

♦ Tensioning Strap - T10038-
♦ 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«.

150

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.

23 ; Diesel Direct Injection System; Overview - Air Filter .

– 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.

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

151

Use pliers to remove the lock washer. Do not use a sharp-

edged lever. Otherwise the selector lever cable could get

damaged.

Remove the cable bracket -A- and selector lever cable from

the transmission, if necessary. To do this, remove the bolts

-arrows-. These bolts must be replaced.

Bolt tightening specification -arrows-: 8 Nm +90° additional

turn.

– Remove the selector lever cable from the ball head on the se‐

lector lever using, for example, a Pry Lever - 80-200- .

The selector lever cable can also be slid back slightly from the

cable bracket and later removed when lowering transmission. Pay

attention to the selector lever cable when lowering the transmis‐

sion.

Caution

Risk of damaging transmission components.

♦ Never touch the contacts in the transmission connector.

The control module as well as the Mechatronic can be de‐

stroyed by static discharge.

– To discharge any static electricity, touch vehicle ground with

hand (without wearing a glove). Refer to 

⇒ page 12

 .

– Release the connector lock on the Mechatronic by pulling in

the direction of the -arrow- and remove the connector.

– Remove the upper bolts between the engine and the trans‐

mission.

These tools are suitable for this.

152

 

 

 

 

 

 

 

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