Volkswagen Golf/Jetta/Cabriole 1990-1999

Manual Transaxle Assembly

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REMOVAL & INSTALLATION



Cabriolet

NOTE
If equipped with electronically theft-protected radio, obtain the security code before disconnecting the battery.

  1. Remove the battery.
  2.  
  3. Detach the backup light switch connector and the speedometer cable from the transaxle. Plug the speedometer cable hole.
  4.  
  5. Turn the crankshaft to align the timing marks to TDC.
  6.  
  7. To disconnect the shift linkage, pry open the ball joint ends and remove both selector rods. Remove the pin, disconnect the relay rod and put the pin back in the hole on the rod for safe keeping.
  8.  
  9. Raise and safely support the vehicle and remove the front wheels. Connect the engine sling tool VW-10-222A or equivalent, to the loop in the cylinder head and just take the weight of the engine off the mounts. Do not try to support the engine from below.
  10.  
  11. Remove the drain plug and drain the oil from the transaxle.
  12.  
  13. Detach the clutch cable from the linkage and remove it from the transaxle case.
  14.  
  15. Remove the starter and front engine mount. On 16 valve engines, remove the engine damper.
  16.  
  17. Remove the small cover behind the right halfshaft flange and remove the clutch cover plate.
  18.  
  19. Disconnect the halfshafts from the drive flanges and hang them up with wire. Do not let them hang by the outer CV-joint or the joint may come apart.
  20.  
  21. Remove the long center bolt from the left side transaxle mount.
  22.  
  23. Remove the entire rear mount assembly from the body and differential housing.
  24.  
  25. Lower the engine hoist enough to let the left mount free of the body and remove the mount from the transaxle.
  26.  
  27. Place a support jack under the transaxle, remove all the transaxle-to-engine bolts and carefully pry the transaxle away from the engine. Lower the transaxle from under the vehicle.
  28.  

To install:

  1. Coat the input shaft lightly with molybdenum grease and carefully fit the transaxle onto the engine. If necessary, put the transaxle in any gear and turn an output flange to align the input shaft spline with the clutch spline.
  2.  
  3. Install the engine-to-transaxle bolts and tighten to 55 ft. lbs. (75 Nm).
  4.  
  5. When installing the mounts to the transaxle, tighten the bolts to 33 ft. lbs. (45 Nm). Install but do not tighten the bolts that go into the rubber mounts.
  6.  
  7. Install the starter and front mount.
  8.  
  9. With all mounts installed and the transaxle safely in the vehicle, allow some slack in the lifting equipment. With the vehicle safely supported, shake the engine/transaxle as a unit to settle it in the mounts. Tighten all mounting bolts, starting at the rear and working forward. Tighten the rubber mount bolts to 25 ft. lbs. (35 Nm). Tighten the front mount bolts to 38 ft. lbs. (52 Nm).
  10.  
  11. Install the halfshafts and tighten the bolts to 33 ft. lbs. (45 Nm). Install the clutch cover plates.
  12.  
  13. Connect the shift linkage and clutch cable and adjust as required.
  14.  
  15. Complete the remaining installation and refill the transaxle with oil.
  16.  

Fox With 4-Speed Transaxle
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the exhaust pipe from the manifold and its bracket on the transaxle.
  4.  
  5. Remove the square-headed bolt on the shift linkage. Later models have a hex head bolt.
  6.  
  7. Press the shift linkage coupling off.
  8.  
  9. Disconnect the clutch cable.
  10.  
  11. Disconnect the speedometer cable.
  12.  
  13. Detach the halfshafts from the transaxle.
  14.  
  15. Remove the starter.
  16.  
  17. Remove the inspection plate.
  18.  
  19. Remove the engine-to-transaxle bolts.
  20.  
  21. Remove the transaxle crossmember.
  22.  
  23. Support the transaxle with a jack.
  24.  
  25. Pry the transaxle out from the engine.
  26.  
  27. Lift the transaxle out of the car with an assistant.
  28.  

To install:

  1. Connect the transaxle to the engine. Tighten the bolts to 40 ft. lbs. (55 Nm).
  2.  
  3. Install the transaxle crossmember. Do not fully tighten the bolts until the transaxle is aligned and fully installed in the vehicle. On models with the rubber core rear transaxle mount, the rubber core must be centered in its housing.
  4.  
  5. Install the starter and inspection plate.
  6.  
  7. Install the axle shafts. Tighten the bolts to 33 ft. lbs. (45 Nm).
  8.  
  9. Connect the speedometer and clutch cables.
  10.  
  11. Connect the shift linkage.
  12.  
  13. Connect the exhaust pipe to the manifold.
  14.  
  15. If necessary, refill the transaxle. Refer to Section 1 for procedures.
  16.  
  17. Adjust the clutch.
  18.  
  19. Connect the negative battery cable.
  20.  

Fox With 5-Speed Transaxle
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the upper engine-to-transaxle bolts.
  4.  
  5. Disconnect the clutch cable from the clutch lever and route the cable off to the side and out of the way.
  6.  
  7. Disconnect the speedometer cable from the transaxle.
  8.  
  9. Disconnect the exhaust pipe from the manifold and its bracket on the transaxle.
  10.  
  11. Remove the engine stop bolts from the block.
  12.  
  13. Disconnect the front exhaust pipe from the catalytic converter.
  14.  
  15. Unbolt the exhaust pipe support from the transaxle.
  16.  
  17. Unbolt the axleshafts from the transaxle flanges. Tie the shafts up and out of the way.
  18.  
  19. Unplug the back-up switch wire.
  20.  
  21. Unbolt and remove the cover plate.
  22.  
  23. Remove the starter.
  24.  
  25. Remove the bolt from the shift rod coupling and pry the linkage from the coupling.
  26.  
  27. Pull the shift rod coupling from the shift rod.
  28.  
  29. Support the transaxle with a jack or support tool 2071 and raise the transaxle slightly.
  30.  
  31. Remove the transaxle support bar bolts and pivot the support to the rear. Remove the support bar mount.
  32.  
  33. Remove the lower engine/transaxle bolts.
  34.  
  35. Using a large prybar, separate the transaxle from the engine and lower it from the vehicle using the jack.
  36.  

To install:

  1. Make sure the mainshaft splines are clean, then lightly lubricate them with molybdenum disulfide grease or spray.
  2.  
  3. Raise the transaxle onto the engine and install the lower engine/transaxle bolts. Tighten the bolts to 40 ft. lbs. (55 Nm).
  4.  
  5. Install the mounts and mounting support brackets. Tighten the transaxle mounting fasteners to the following specifications:
    1. Subframe support-to-body-40 ft. lbs. (55 Nm).
    2.  
    3. Mount-to-bracket-18 ft. lbs. (25 Nm).
    4.  
    5. Mount-to-body-80 ft. lbs. (108 Nm).
    6.  
    7. Front bracket-to-transaxle -40 ft. lbs. (55 Nm).
    8.  

  6.  


NOTE
Make sure the engine/transaxle mounts are aligned and free of tension before tightening the fasteners. All the mount rubber cores should be centered in the mount.

  1. Connect the shift rod coupling to the shift rod.
  2.  
  3. Connect the shift rod linkage to the shift rod coupling. Tighten the shift rod bolt to 14 ft. lbs. (19 Nm).
  4.  
  5. Install the starter. Tighten the starter mounting bolts to 14 ft. lbs. (19 Nm).
  6.  
  7. Install the cover plate and tighten the bolts to 7 ft. lbs. (10 Nm). Make sure the cover plate is properly seated.
  8.  
  9. Plug in the back-up switch wire.
  10.  
  11. Connect the axleshaft to the transaxle. Tighten the flange bolts to 30 ft. lbs. (40 Nm).
  12.  
  13. Attach the exhaust pipe support to the transaxle.
  14.  
  15. Connect the front exhaust pipe to the catalytic converter.
  16.  
  17. Install the engine stop bolts and tighten them to 18 ft. lbs. (25 Nm).
  18.  
  19. Connect the exhaust pipe to the bracket and manifold. Tighten the manifold nuts to 22 ft. lbs. (30 Nm).
  20.  
  21. Connect the speedometer and clutch cables.
  22.  
  23. Install the upper engine/transaxle bolts. Tighten the bolts to 40 ft. lbs. (55 Nm).
  24.  
  25. Connect the negative battery cable.
  26.  

1990-92 Golf and Jetta

NOTE
If equipped with electronically theft-protected radio, obtain the security code before disconnecting the battery.

  1. Remove the battery.
  2.  
  3. Detach the backup light switch connector and the speedometer cable from the transaxle; plug the speedometer cable hole.
  4.  
  5. Remove the upper engine-to-transaxle bolts.
  6.  
  7. Remove the 3 right side engine mount bolts, between the engine and firewall.
  8.  
  9. To disconnect the shift linkage, pry open the ball joint ends and remove the shift and relay shaft rods.
  10.  
  11. Remove the center bolt from the left transaxle mount.
  12.  
  13. Raise and safely support the vehicle and remove the front wheels. Connect the engine sling tool VW-10-222A or equivalent, to the loop in the cylinder head and just take the weight of the engine off the mounts. On the 16 valve engine, the idle stabilizer valve must be removed to attach the tool. Do not try to support the engine from below.
  14.  
  15. Remove the drain plug and drain the oil from the transaxle.
  16.  
  17. Remove the left inner fender liner.
  18.  
  19. Disconnect the halfshafts from the inner drive flanges and hang them from the body.
  20.  
  21. Remove the clutch cover plate and the small plate behind the right halfshaft flange.
  22.  
  23. Remove the starter and front engine mount.
  24.  
  25. Disconnect the clutch cable and remove it from the transaxle housing.
  26.  
  27. Place a jack under the transaxle and remove the last bolts holding it to the engine. Remove the remaining transaxle mount bolts and mounts.
  28.  
  29. Carefully pry the transaxle away from the engine and lower it from the vehicle.
  30.  

To install:

  1. Coat the input shaft lightly with molybdenum grease and carefully fit the transaxle in place. If necessary, put the transaxle in any gear and turn an output flange to align the input shaft spline with the clutch spline.
  2.  
  3. Install the engine-to-transaxle bolts and tighten to 55 ft. lbs. (75 Nm).
  4.  
  5. When installing the mounts to the transaxle, tighten the rear bracket-to-engine bolts and the transaxle support bolts to 18 ft. lbs. (25 Nm). Tighten the left bracket-to-transaxle bolts to 25 ft. lbs. (35 Nm) and the remaining mounting bolts to 44 ft. lbs. (60 Nm). Install but do not tighten the bolts that go into the rubber mounts.
  6.  
  7. Install the starter and front mount.
  8.  
  9. With all mounts installed and the transaxle safely in the vehicle, allow some slack in the lifting equipment. With the vehicle safely supported, shake the engine/transaxle as a unit to settle it in the mounts. Tighten all mounting bolts, starting at the rear and working forward. Tighten the bolts that go into the rubber mounts to 44 ft. lbs. (60 Nm).
  10.  
  11. Install the halfshafts and tighten the bolts to 33 ft. lbs. (45 Nm). Install the clutch cover plates.
  12.  
  13. Connect the shift linkage and clutch cable and adjust as required.
  14.  
  15. Install the inner fender and complete the remaining installation. Refill the transaxle with oil.
  16.  

1995-99 Cabrio, 1993-99 Golf and Jetta


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Fig. Location of upper transaxle bolts



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Fig. Mark the exact location of each bolt. There will be bolts of different size, thread pitch, and design



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Fig. Detaching the bracket from the starter



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Fig. Remove the clutch cable from the bottom of the cable (transmission side)



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Fig. Disconnecting the shifter weight from the transmission by pulling the cotter pin and lifting up



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Fig. Location of the shift weight



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Fig. Remove all wiring harnesses from the transmission



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Fig. View of the rear motor mount support bracket



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Fig. Manual transmission input shaft

  1. Raise and support the vehicle.
  2.  
  3. Detach the negative battery cable.
  4.  
  5. The removal of the front body clip, radiator, cooling fans, and the hook and lock mechanism is not required but will greatly increase the accessibility of the transaxle.
  6.  
  7. Remove all electrical wiring from the transaxle.
  8.  
  9. Remove all ground straps from the transaxle housing.
  10.  
  11. Support the transmission.
  12.  
  13. Detach the gearshift selector rods/cables.
  14.  
  15. Remove the support bracket from the rear of the transaxle assembly.
  16.  
  17. Remove the clutch shield plate.
  18.  
  19. Detach the drive axles at the transmission, tie the drive axles up and out of the way.
  20.  
  21. Position the steering wheel to full lock left.
  22.  
  23. Remove all but two of the transmission bellhousing bolts.
  24.  
  25. Remove the front engine mounting crossmember.
  26.  
  27. Remove the remaining bell housing bolts and then pull the transaxle from the engine.
  28.  

To install:

  1. Installation is the reverse of removal.
  2.  

 
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