Front wheel drive models
The vehicle must be raised and secured so that you can work both in the engine compartment and underneath the vehicle. KP is removed downwards.
Important: Due to the different lengths and diameters of the screws, be sure to mark their location on the engine/gearbox flange or mark them with adhesive tape.
Remove connection wire from «weight» battery.
Unscrew the wire connecting the gearbox to the body.
Remove the plug of the speed sensor on the gearbox; to do this, depress the clamps of the plug. Repeat the same with the plug to the reversing light switch.
On a 6-cylinder engine, remove the part of the intake pipe between the air filter and the intake manifold.
Loosen the bolts accessible from above between the engine and gearbox.
Loosen the cable ties, disconnect the plug connection to the lambda probe.
Disconnect the bottom panel of the engine compartment (chapter «Body elements»).
Unscrew the wire connecting the gearbox to the body.
Disconnect the front exhaust pipe from the manifold.
Remove the traverse under the gearbox.
Remove the gearbox shift fork rod.
Disconnect procon-ten cables from gearbox.
Remove the protective sheet of the drive axle on the right (in a 6-cylinder engine - and on the left).
Remove the drive axles to the right and left of the gearbox, unscrew the hinges to the left (while holding the ends of the shafts) and tie up both drive shafts.
Remove the hydraulic clutch slave cylinder; the pipeline may remain connected.
If present, unscrew the thermal protection of the right rubber-metal support.
Remove starter.
On vehicles with a 4-cylinder engine, remove the protective sheet from the clutch housing.
Protect the engine with stands from tipping forward or backward
Bring a garage jack under the gearbox from below.
Remove the fixing bolts of the gearbox cross member / attachment bracket.
Remove front engine mount (torque support in 5- and 6-cylinder engines).
Remove the lower bolts connecting the engine and gearbox.
Carefully press the gearbox away from the engine using a pry bar.
Now carefully lower the gearbox on the jack.
To install, clean spline connection of gearbox input shaft and lubricate with MoS2 paste or VW-Fett G 000 100 grease.
Check whether the guide bushes for centering the gearbox have entered the engine block.
Check and, if necessary, adjust the gear shifting with the gearbox installed.
Install the clutch slave cylinder only with an integrated gearbox (see chapter «Clutch»).
See the table on the next page for tightening torques.
Removing the manual transmission. Behind the gearbox is suspended on the left and right on the so-called traverse (arrow). The connection with the bracket of mounted units is formed by an elastic rubber-metal support.
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