6.3 Removing and Installing Transaxle

The transaxle must be removed from the car for most internal repairs or for replacement. In the procedure given below, the transaxle is separated from the engine, supported on a jack, and removed from below. Alternatively, the engine and transaxle assembly can be removed, as described in ENGINE, and the transaxle then separated from the engine.

Removal of the transaxle requires a means of lifting the engine, a transmission jack or a floor jack with transmission adaptor, and jack stands to support the car. The engine lift is necessary because the engine mounts are removed. Use extreme caution when working beneath the car and lowering the transaxle.

To remove:

1.	Disconnect the battery negative (-) terminal. Disconnect the ground strap from the transaxle. Disconnect the electrical connector from the reverse/upshift light switch atop the transaxle.

2.	Remove the speedometer cable and insert a plug in the hole to prevent loss or contamination of the transaxle lubricant.

3.	Disconnect the clutch cable from the clutch release lever as described in 5.1 Clutch Cable.

4.	Loosen the left front wheel lug bolts. Then jack up the front of the vehicle, support it securely, and remove the left front wheel.

5.	Remove the short selector rod and the long connecting link from the two relay levers of the shift linkage. If necessary, see 4. Shift Mechanism.

6.	Install an engine support, as shown in Fig. 6-14, and increase tension until it supports the weight of the engine.

Fig. 6-14.

Engine being supported by support tool. Volkswagen special tool no. 10-222A shown. Inset shows special tool 3180 for use on 16-valve models.

7.	Remove the upper bolts that hold the transaxle to the engine.

8.	Remove the three bolts from the right rear engine mount as shown in Fig. 6-15.

Fig. 6-15.

Typical right rear engine mounting bolts a.

9.	Remove the center bolt from the left rear transaxle mount as shown in Fig. 6-16, then remove the two through-bolts and nuts holding the mount's support arm to the transmission.

Fig. 6-16.

Typical left transaxle mounting bolt a that needs to be removed. Arrow indicates support arm.

10.	Remove the left and right drive axles from the transaxle drive flanges as described in SUSPENSION AND STEERING.

11.	Remove the left wheelhouse liner mounting screws and washers, and remove the wheelhouse liner.

12.	Remove the bolts from the clutch cover plate as indicated in Fig. 6-17 (the cover plate will remain on the engine when the transaxle is removed). Remove the bolts from the small cover plate (located behind the left drive flange).

Fig. 6-17.

Clutch cover plate bolts at 1 and small cover plate bolts at 2.

13.	Place a transmission jack or a floor jack with transmission adaptor beneath the transaxle. Raise the jack just enough to support the transaxle. Do not raise the engine.

14.	On 16-valve engines, remove the engine damper.

15.	Remove the starter as described in ELECTRICAL SYSTEM.

16.	Remove the front engine and transaxle mount as shown in Fig. 6-18. Completely remove it from the car.

Fig. 6-18.

Front hydraulic engine/transaxle mounting bolts a. Earlier rubber mount is similar.

17.	Slightly lower the transaxle and remove the left mounting bolt that was concealed by the small cover plate, where applicable.

18.	Push the engine and transaxle assembly as far as possible toward the passenger side of the car. Remove the remaining lower mounting bolts holding the transaxle to the engine.

19.	Separate the transaxle from the engine, taking care not to place any strain on the transmission main shaft, and either lower the jack or raise the car until there is enough clearance to remove the transaxle. Pull the transaxle out from under the car.