REMOVAL & INSTALLATION
Dasher and Quantum
The following procedures are for both types of Dasher automatic transaxles (003 and the 089). The model designation numbers are visible on the top of the automatic transaxle unit (as opposed to the differential unit of the transaxle). Another way to identify the transaxle is that type 003 has a vacuum modulator hose coming from the driver's side front of the transaxle above the pan, while type 089 does not. Do not confuse the transaxle fluid filler pipe with the above mentioned hose.
- Disconnect the negative battery cable.
- Raise the car and safely position support stands so that you will have free access to the transaxle and axle shafts.
- Disconnect the speedometer cable.
- On the 089 transaxle, remove the accelerator cable from the throttle valve housing.
- Remove two of the upper engine/transaxle bolts. On the 089 transaxle, support the engine with either VW special tool 10-222 or an appropriate jack.
- Disconnect the exhaust pipe.
- Remove the torque converter cover plate. On the 003 transaxle, remove the vacuum modulator hose.
- Remove the circlip holding the selector lever cable to the lever, then remove the cable.
- Remove the starter.
- On the 003 disconnect the kickdown switch wires.
- The torque converter is mounted to the flywheel by three bolts. The bolts are accessible through the starter hole. You'll have to turn the engine over by hand to remove all three.
- Remove the axle shaft to transaxle socket head bolts.
- Matchmark the position of the ball joint on the left control arm and remove the ball joint from the arm. Hold the wheel assembly out away from the arm to provide clearance between the axle shaft and the transaxle.
On Quantum Syncro models, the driveshaft connected to the rear axle assembly will also have to be removed in order to remove the transaxle.
- Remove the exhaust pipe from the transaxle bracket.
- Disconnect the remaining transaxle controls. Those you cannot reach can be removed when the transaxle is lowered a little.
- Unbolt the transaxle crossmember and remove it from the transaxle.
- Support the transaxle on a jack and loosen the lower engine/transaxle bolts.
- On the 089 transaxle, remove all engine/transaxle bolts. Have an assistant pull the left wheel out as far as it will go and slowly lower the transaxle, making sure the torque converter does not fall off.
- On the 003 transaxle, loosen the union nut on the ATF filler pipe so that the pipe can be swivelled. Remove the engine/transaxle bolts and lower the unit. You may have to pull the left wheel out a little so that the axle shaft clears the transaxle case. Make sure the torque converter does not fall off.
Installation is the reverse of removal. Be sure to observe the following:
The torque converter nipple must be about 21mm from the bellhousing face surface. If it sticks out further than this, the oil pump shaft has pulled out. To correct this, realign the converter and shaft.
See Figures 1 and 2
The engine and transaxle may be removed together, as explained under the engine removal and installation procedure in Engine & Engine Overhaul , or the transaxle may be removed alone, as explained here.
- Disconnect both battery cables.
- Disconnect the speedometer cable at the transaxle.
- Support the left end of the engine at the lifting eye. Attach a hoist to the transaxle.
- Unbolt the rear transaxle carrier from the body, then from the transaxle. Unbolt the left-side carrier from the body.
- Unbolt the driveshafts and wire them up.
- Remove the starter.
- Remove the three converter to drive plate bolts.
- Shift into Park and disconnect the floorshift linkage at the transaxle.
- Remove the accelerator and carburetor cable bracket at the transaxle.
- Unbolt the left-side transaxle carrier from the transaxle.
- Unbolt the front transaxle mount from the transaxle.
- Unbolt the bottom of the engine from the transaxle. Lift the transaxle slightly, swing the left driveshaft up, remove the rest of the bolts, pull the transaxle off the mounting dowels, and lower the transaxle out of the car. Secure the converter so it doesn't fall out.
Don't tilt the torque converter! Fluid will spill out.To install:
- Push the transaxle onto the mounting dowels and install two bolts. Be sure the torque converter is fully seated on the one-way clutch support (indicated by the longer arrow). Distance "a" should be 1.18 in. (30mm). Lift the unit until the left driveshaft can be installed, then install and torque the remaining bolts to 39 ft. lbs. (53 Nm). Align the transaxle so that the left mount is in the center of the body mount. Both sides' dimension "X" should be equal.
- Tighten the front transaxle mount bolts to 39 ft. lbs. (53 Nm). Install the left-side transaxle carrier to the transaxle.
- Connect the accelerator and carburetor cable bracket. Connect the floorshift linkage.
- Tighten the torque converter to drive plate bolts to 22 ft. lbs. (30 Nm). Torque the driveshaft bolts to 33 ft. lbs. (45 Nm).
- Connect the speedometer cable and battery cables.
- Disconnect both battery cables.
- Withdraw the speedometer drive gear, then plug the hole in the transaxle.
- With the vehicle on the ground, remove the front axle nuts.
- Raise and safely support the vehicle, then remove the front wheels. Connect the engine sling tool VW-10-222A or equivalent sling, to the cylinder head and just take the weight of the engine off the mounts. On 16-valve engines, the idle stabilizer valve must be removed to attach the tool. Do not try to support the engine from below.
- Remove the driver's side rear transaxle mount and support bracket.
- On Golf and Jetta, remove the front mount bolts from the transaxle and from the body and remove the mount as a complete assembly.
- Remove the selector and accelerator cables from the transaxle lever but leave them attached to the bracket. Remove the bracket assembly to save the adjustment.
- Remove the halfshafts.
- Remove the heat shield and brackets and remove the starter. On Scirocco and Cabriolet, the front mount comes off with the starter.
- Remove the bellhousing lower cover and turn the engine as needed to remove the torque converter-to-flywheel bolts.
- Remove the remaining transaxle mounts and, on Golf and Jetta, the subframe bolts and allow the subframe to hang free.
- Support the transaxle with a jack and remove the remaining engine-to-transaxle bolts. Be careful to secure the torque converter so it does not fall out of the transaxle.
- Carefully lower the transaxle from the vehicle.
- When reinstalling, make sure the torque converter is fully seated on the pump shaft splines. The converter should be recessed into the bell housing and turn by hand. Keep checking that it still turns while drawing the engine and transaxle together with the bolts.
- Install the engine-to-transaxle bolts and torque to 55 ft. lbs. (75 Nm).
- Install all mount and subframe bolts before tightening any of them. Tighten the bolts starting at the rear and work forward. Torque the smaller bolts to 25 ft. lbs. (34 Nm) and the larger bolts to 58 ft. lbs. (80 Nm). Remove the lifting equipment when all mounts are installed.
- Install the torque converter-to-flywheel bolts and torque them to 26 ft. lbs. (35 Nm).
- Install the starter and torque the bolts to 14 ft. lbs. (20 Nm). Install the heat shields.
- Make sure the halfshaft splines are clean and apply a thread locking compound to the splines before sliding it into the hub. Connect the halfshafts to the drive flanges and torque the bolts to 33 ft. lbs. (45 Nm). Install new axle nuts, but do not fully torque them until the vehicle is on the ground.
- If removed, fit the ball joints to the control arm and torque the clamping bolt to 37 ft. lbs. (50 Nm).
- Connect and adjust the shift linkage as required.
- When assembly is complete and the vehicle is on its wheels, torque the axle nuts to 195 ft. lbs. (265 Nm) on Golf and Jetta, or 175 ft. lbs. (240 Nm) on Scirocco and Cabriolet.
- Unplug the hole in the transaxle, and insert the speedometer drive gear.
- Connect the battery cables.