Removing and installing transmission

To remove the gearbox, proceed as follows:

- Disconnect the battery. If the radio with a device to prevent the theft, it is necessary to know the code;

- Disconnect the cable from the clutch release lever, as described in Section. 7.4;

- Remove shown in Fig. 152 the plug connector. It is connected to the speedometer;

- To find a transmission shown in Fig. 153 of the plug connector 1 reversing light switch and remove it. 2 Remove the bolt and disconnect the cable connections to the housing 3. Pull the plug holder pads from the mount on the gearbox;

- Disconnecting the drive shafts located on the inner side of the gearbox from the flanged joints, as described in the relevant section. The control mechanism is fully deployed to the left and the left drive shaft secure the cord so that it was as high as possible;

- Disconnect the finger A (Fig. 154) gear for what turn away a bolt 1. Lift and remove the screwdriver shift cable between the gear lever and the gearbox in place of 2;

- Completely remove the balancing suspension located on the underside of the gearbox. To do this, unscrew the nut 1 (Fig. 155) and gently knock the bolt 2. Remove the three screws on the underside 3 equalizer suspension and remove the suspension;

- Remove the intake manifold support and remove it. Remove the air filter cover;

- To disconnect from a starter all electrical wires and remove a starter (see. Sec. "Electrical Equipment");

- Remove the engine from suspension. Volkswagen Service Center uses for this purpose a special device, which is mounted on the fender, as shown in Fig. 156. If this device is not present, perform the following steps:

- To establish a solid steel rod between the folds of the wings of the engine compartment. Put under the rod thick cloth to prevent damage to the metal;

- Wrap the solid steel rod and wire lifting eye and twist the wire twist in the middle until the engine will be under tension. Ensure that when there was tension wires;

- Unscrew the two screws (fig. 157) and remove the left suspension transmission;

- Be brought under the gearbox rolling jack to provide support for the engine and gearbox. Always ensure that the gearbox is securely held jack. Removing the gearbox to hold with the assistant;

- Unscrew the bolts between the engine and gearbox on the lower side;

- Lower the gearbox to the jack. The assistant should operate the jack moving the gearbox. The right side of the engine to be raised to be able to remove the box.

Transmission installation must be performed in sequence, return to removal, taking into account the following:

- Lubricate the crankshaft spline connections with graphite grease. If you removed the drive shaft coupling, it must be installed on the slots and moved to and fro to ensure ease of movement;

- Check the number of plugs used for centering the gearbox on the engine, the engine block. Otherwise remove the sleeve from the gearbox, and rearrange them in the block;

- Check whether the intermediate plate on the motor bushings seat in the block and there is danger that it will fall;

- Calibration thread on the pin gear via tap M8. A bolt, which is always necessary to replace the processed fluid. It prevents it from unscrewing and remains on the thread. Therefore, when screwing a new screw can be problems if the thread is not clear;

- A new bolt in conjunction thrust transmission shift fork tightening torque of 20 Nm;

- When installing the gearbox ensure that the engine mount securely verified by level. Otherwise, after installation, you must hold them centering without stress;

- Set equalizer suspension. Tighten the nut 1 (Fig. 155) and the bolt 2 to 50 N ?� m and the three screws on the underside to 25 N ?� m (if the car is made before the end of 1995) and 35 N ?� m (since 1996) ;

- Tighten the two screws indicated in Fig. 157 arrows left suspension transmission torque of 50 Nm;

- Observe the following tightening torques during installation. Fig. 158 shows the location of the mounting bolts between the engine and transmission. Not all of the bolts are the same length.

When installing (Fig. 158), tighten the bolts next moment Nm: 1 bolt (M8h65) - 20; bolt 2 (M8h70) - 20; bolt 3 (M8h160) - 20; bolt 4 (M12h62) - 80; Bolt 5 (M7h12) - 15; Bolt 6 (M12h70) - 80.

- Tighten the intake manifold support to 25 Nm;

- Check the adjustment of the clutch mechanism, as described in Section. 7.4;

- Tighten the drive shaft flange to 45 Nm;

- Tighten the bolt finger gear shift fork to thrust transmission torque of 20 Nm.

After setting the gearbox to check the oil level therein, if performed on a transmission operation, for which the following:

- Set the front part of the car on support and move the switching mechanism to the left;

- Remove the gearbox oil filler plug, indicated in Fig. 159 arrow. This will require a hex wrench and the head of "17 mm". To provide access to traffic, requires a universal joint with extension;

- Lower your finger in the hole and check whether the oil is at the lower edge of the oil filler opening;

- After checking screw plug and tighten to 25 Nm.

Pouring oil in the gearbox

If a gearbox must be filled with fresh oil, the oil will require a syringe, which is inserted into the oil hole. Oil is poured until until it comes out of the holes. Thoroughly clean the plug and tighten to 25 Nm.