Volkswagen Air Cooled 1949-1969 Repair Guide

Transaxle Assembly

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REMOVAL & INSTALLATION





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Fig. Fig. 1 To correctly align the automatic transaxle during installation, three aligning tools must be fabricated to the specifications shown



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Fig. Fig. 2 Use the aligning tools as shown to correctly position the transaxle

  1. Remove the battery ground cable.
  2.  
  3. On the sedan, remove the cooling air intake duct with the heating fan and hoses. Remove the cooling air intake connection and bellows, then detach the hoses to the air cleaner.
  4.  
  5. On station wagons, remove the warm air hoses and air cleaner. Remove the boot from between the dipstick tube and the body and the boot from between the oil filler neck and the body. Disconnect the cooling air bellows at the body.
  6.  
  7. Disconnect the wires at the regulator and the alternator wires at the snap connector located by the regulator. Disconnect the auxiliary air regulator and the oil pressure switch at the snap connectors located by the distributor.
  8.  
  9. Disconnect the fuel injection wiring. There are 12 connections and they are identifiable as follows:
  10.  
    1. Fuel injector cylinder 2: 2-pole, protective gray cap.
    2.  
    3. Fuel injector cylinder 1: 2-pole, protective black cap.
    4.  
    5. Starter: 1-pole, white.
    6.  
    7. Throttle valve switch: 4-pole.
    8.  
    9. Distributor: 3 pole.
    10.  
    11. Thermo switch: 1-pole, white.
    12.  
    13. Cold start valve: 3-pole.
    14.  
    15. Temperature sensor crankcase: 2-pole.
    16.  
    17. Ground connection: 3-pole, white wires.
    18.  
    19. Temperature sensor for the cylinder head: 1-pole.
    20.  
    21. Fuel injector cylinder 3: 2-pole, protective black cap.
    22.  
    23. Fuel injector cylinder 4: 2-pole, protective gray cap.
    24.  

  11. Disconnect the accelerator cable.
  12.  
  13. Disconnect the right fuel return line.
  14.  
  15. Raise the car.
  16.  
  17. Disconnect the warm hoses from the heat exchangers.
  18.  
  19. Disconnect the starter wires and push the engine wiring harness through the engine cover plate.
  20.  
  21. Disconnect the fuel supply line and plug it.
  22.  
  23. Remove the heater booster exhaust pipe.
  24.  
  25. Remove the rear axles and cover the ends to protect them from dirt.
  26.  
  27. Remove the selector cable by unscrewing the cable sleeve.
  28.  
  29. Remove the wire from the kickdown switch.
  30.  
  31. Remove the bolts from the rubber transaxle mountings, taking careful note of the position, number, and thickness of the spacers that are present.
  32.  


CAUTION
These spacers must be reinstalled exactly as they were removed. Do not detach the transaxle carrier from the body.

  1. Support the engine and transaxle assembly in such a way that it may be lowered and moved rearward at the same time.
  2.  
  3. Remove the engine carrier bolts and the engine and transaxle assembly from the car.
  4.  

The top carrier bolts on the Type 2 are the top engine-to-transaxle bolts. Be sure to support the engine/transaxle assembly before completely removing the bolts.

  1. Matchmark the flywheel to the torque converter and remove the three attaching bolts.
  2.  
  3. Remove the engine-to-transaxle bolts and separate the engine and transaxle.
  4.  


CAUTION
Exercise care when separating the engine and transaxle, as the torque converter will easily slip off the input shaft if the transaxle is tilted downward.

To install:

  1. Install and tighten the engine-to-transaxle bolts after aligning the matchmarks on the flywheel and converter.
  2.  
  3. Making sure the matchmarks are aligned, install the converter-to-flywheel bolts.
  4.  
  5. Make sure the rubber buffer is in place and the two securing studs do not project more than 0.7 in. from the transaxle case.
  6.  
  7. Tie a cord to the slot in the engine compartment seal. This will make positioning the seal easier.
  8.  
  9. Lift the assembly far enough to allow the accelerator cable to be pushed through the front engine cover.
  10.  
  11. Continue lifting the assembly into place. Slide the rubber buffer into the locating tube in the rear axle carrier.
  12.  
  13. Insert the engine carrier bolts and raise the engine until the bolts are at the top of their elongated slots. Tighten the bolts.
  14.  

A set of three gauges must be obtained to check the alignment of the rubber buffer in its locating tube. The dimensions are given in the illustration as is the measuring technique. The rubber buffer is centered horizontally when the 11mm gauge can be inserted on both sides. The buffer is located vertically when the 10mm gauge can be inserted on the bottom side and the 12mm gauge can be inserted on the top side. See Steps 28 and 29 for adjustment procedures.

  1. Install the rubber transaxle mount bolts with spacers of the correct thickness. The purpose of the spacers is to center the rubber buffer vertically in its support tube. The buffer is not supposed to carry any weight; it absorbs torsional forces only.
  2.  
  3. To locate the buffer horizontally in its locating tube, the engine carrier must be vertical and parallel to the fan housing. It is adjusted by moving the engine carrier bolts in elongated slots. Further travel may be obtained by moving the brackets attached to the body. It may be necessary to adjust the two rear suspension wishbones with the center of the transaxle after the rubber buffer is horizontally centered. Take the car to a dealer or alignment specialist to align the rear suspension.
  4.  
  5. Adjust the selector level cable.
  6.  
  7. Connect the wire to the kickdown switch.
  8.  
  9. Install the rear axles. Make sure the lockwashers are placed with the convex side out.
  10.  
  11. Reconnect the fuel hoses and heat exchanger hoses. Install the pipe for the heater booster.
  12.  
  13. Lower the car and pull the engine compartment seal into place with the cord.
  14.  
  15. Reconnect the fuel injection and engine wiring. Push the starter wires through the engine cover plate and connect the wires to the starter.
  16.  
  17. Install the intake duct with the fan and hoses, as well as the cooling air intake.
  18.  

 
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