Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 501

2

Transmission, Removing and Instal‐

ling

⇒ “2.1 Transmission, Removing”, page 76
⇒ “2.2 Transmission, Installing”, page 92
⇒ “2.3 Transmission Tightening Specifications”, page 104

2.1

Transmission, Removing

⇒ “2.1.1 Transmission, Removing, Vehicles with Turbo Diesel

Engine”, page 76
⇒ “2.1.2 Transmission, Removing, Vehicles with Gasoline En‐

gine”, page 83

2.1.1

Transmission, Removing, Vehicles with

Turbo Diesel Engine

Special tools and workshop equipment required
♦ Engine Support Bridge - 10-222A-
♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12-
♦ Engine Support Bridge - Engine Support 31 - Adapter 1 -

10-222A/31-1-

♦ Engine Support Bridge - Engine Support 31 - Adapter 2 -

10-222A/31-2-

♦ Engine Support Bridge - Engine Support 29 - 10-222A/29-
♦ Engine Support - Basic Set - Square Pipe - T40091/1-
♦ Engine Support - Basic Set - Movable Joint - T40091/3-
♦ Engine Support Brackets - T40093/3- from Engine Support -

Supplement Kit - T40093A-

♦ Engine Support Brackets - T40093/3-6-
♦ Transmission Support - 3282-
♦ Transmission Support - Mounting Plate 33 - 3282/33-
♦ Transmission Support Jig - 3336- to transport the transmis‐

sion.

♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
♦ Engine and Gearbox Jack - VAS6931-

Caution

This procedure contains mandatory replaceable parts. Refer

to component overview prior to starting procedure.

Mandatory Replacement Parts
♦ Nut - Selector Lever to Shift Lever Shaft with Shift Lever Cover
♦ Lock Washer - Cable Retainer to Selector Lever
♦ Lock Washer - Cable Mounting Bracket to Cable Retainer
♦ Bolt - Pendulum Support to Transmission
♦ Bolt - Transmission Bracket to Transmission

– If the -10-222A- does not yet have a hole with an -arrow-

marked on it, do so now.

• Dimension -a- = 225mm
• Hole diameter = 12.5 mm

– Disconnect the battery ground cable. Refer to ⇒  Electrical

Equipment; Rep. Gr.  27 ; Battery; Battery, Disconnecting and

Connecting .

– Remove the engine cover. Refer to ⇒  Rep. Gr.  10 ; Engine

Cover; Engine Cover, Removing and Installing .

– Remove the air filter housing. Refer to ⇒  Engine Mechanical,

Fuel Injection and Ignition; Rep. Gr.  24 ; Air Filter; Air Filter

Housing, Removing and Installing .

– Remove the battery and the battery tray -1- -arrows-. Refer to

⇒  Electrical Equipment; Rep. Gr.  27 ; Battery; Battery, Dis‐

connecting and Connecting .

– Remove the shift cable lock washer -1- from the transmission

selector lever -2-. Remove the cable from the pin -arrow-.

– Remove the cable retainer from the selector cable.
• To avoid damage to the selector cable, the cable retainer must

be disconnected from the selector lever before removal.

– Pull the safety mechanism all the way forward in the direction

of -arrow 1-. Then lock it to the left in the direction of

-arrow 2-.

– Push the relay lever forward (in the direction of -arrow 3-).

Note

Only remove the cable retainer when the relay lever is removed.

Refer to

⇒ Fig. ““With the Selector Relay Lever Removed: Pry the Selector

Cable Retainer Out of the Selector Relay Lever.”“ , page 67

 .

– Remove nut -1- and bolts -2- and set the cable bracket and

cables off to the side.

Note

Brake fluid must not come into contact with the longitudinal mem‐

ber or transmission. If it does, clean the area thoroughly.

– Unclamp the supply hose to the clutch master cylinder with a

-3094- .

Note

♦

A slight deformation of the supply hose remains after the

-3094- has been unclamped.

♦

The supply hose is therefore not defective.

♦

After removing the -3094- , the supply hose must be formed

back into its original shape.

– Place a lint-free cloth under the bleeder.
– Remove the clip -arrow- all the way and then remove the hose/

line assembly -A- from the bleeder.

– Tie up wire.
The ground cable -B-, if present, is installed later in the procedure.
– Seal the open lines and connections with clean plugs from the

-VAS6122- .

Caution

There is a risk of contamination from the leaking brake fluid.

♦ Do not use the clutch pedal if the hose/line assembly from

the clutch slave cylinder bleeder is disconnected.

– Remove the upper engine/transmission connecting bolts

-arrows-.

– Remove windshield wiper arms. Refer to ⇒  Electrical Equip‐

ment; Rep. Gr.  92 ; Windshield Wiper System; Windshield

Wiper Arms, Removing and Installing .

– Remove the plenum chamber cover. Refer to ⇒  Body Exterior;

Rep. Gr.  50 ; Bulkhead; Plenum Chamber Cover, Removing

and Installing .

– Disconnect any hoses and cables in the area of the -10-222A-

lifting eyes on the engine.

– Attach the -10-222A- as follows:
The following are needed:
♦ -10-222A/31-1-
♦ -10-222A/31-2-
♦ -10-222A/12-
♦ -T40091/1-
♦ -T40091/3-
♦ -T40093A/3-
♦ -T40093/3-6-
– Remove caps above the front suspension strut bolted con‐

nections.

– Place the -10-222A/31-1- and -10-222A/31-2- on the suspen‐

sion strut mounts.

The tabs -arrow- face the engine compartment.

– Slide the -T40091/3- onto the -10-222A- .
– Fasten the -10-222A- on the -10-222A/31-1- and on the

-10-22 /31-2- .

-A- is the -T40093/3-6- (refer to the next illustration)