Mechanics

DOING A CLUTH JOB ON THIS 99 VW 2.8L ,DOES THE LOWER CRADDLE NEED TO BE REMOVED TO PULL THE TRANS?

1999 Volkswagen Jetta • 140,000 miles

Have all bolts removed and trans seperated and cant get trans out and to the ground, do I need to disconnect the rack and lower the lower craddle topull the trans?
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Eriktherdd
January 5, 2012.




5 SPD. MANUAL TRANSMISSION 02A (A3 PLATFORM) -1999 Volkswagen Jetta GL
Page 1 of 5
TRANSMISSION, REMOVING AND INSTALLING

Removing

? Disconnect Battery Ground (GND) strap and remove Battery.
CAUTION: On vehicles equipped with an anti-theft radio, make sure you
know the correct radio activation code before disconnecting the battery.
? Remove radiator cover. ? Remove battery bracket.
? Disconnect harness connectors from Speedometer Vehicle Speed Sensor (VSS) (G22) -arrow 1- and Back-Up Light Switch (F4) -arrow 2-.
Fig. 47: Disconnecting Harness Connectors From Speedometer Vehicle Speed Sensor And Back Up Light Switch
Courtesy of VOLKSWAGEN OF AMERICA, INC.
? Disconnect all other electrical connections and Ground (GND) connections from engine/transmission mounting bolts.
? Remove bolt (-arrow-) at right-side engine mount.
Fig. 48: Removing Bolt At Right-Side Engine Mount Courtesy of VOLKSWAGEN OF AMERICA, INC.
? Remove bracket -A- for harness connector, if applicable.
? Remove balance weight -A- and disconnect gear selector cable -B- from gear selector lever. ? Disconnect gate selector cable -C- at actuating arm/relay lever by pulling tab in direction of -
arrow-.
Fig. 49: Removing Balance Weight -A- And Disconnecting Gear Selector Cable -B- From Gear Selector Lever
Courtesy of VOLKSWAGEN OF AMERICA, INC.
? Remove cable bracket bolts (-arrows-) at transmission.
Fig. 50: Removing Cable Bracket Bolts At Transmission Courtesy of VOLKSWAGEN OF AMERICA, INC.
? Remove clutch slave cylinder and lay to one side.? Secure with wire
? DO NOT open clutch hydraulic system
Fig. 51: Removing Clutch Slave Cylinder And Lay To One Side Courtesy of VOLKSWAGEN OF AMERICA, INC.

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5 SPD. MANUAL TRANSMISSION 02A (A3 PLATFORM) -1999 Volkswagen Jetta GL
Page 2 of 5
? Remove hex bolt -A- on left transmission mount -B-.
NOTE: To do so, disconnect coolant overflow reservoir and lay it aside.
Fig. 52: Removing Hex Bolt -A- On Left Transmission Mount -B- Courtesy of VOLKSWAGEN OF AMERICA, INC.
? Remove transmission support -A- from transmission (if applicable). ? Remove connector attachment plate from front transmission bracket.
Fig. 53: Removing Transmission Support -A- From Transmission Courtesy of VOLKSWAGEN OF AMERICA, INC.
? Remove bolt (for bracket) on front engine mount.
? Remove engine/transmission upper attachment bolts.
Fig. 54: Removing Bolt (For Bracket) On Front Engine Mount Courtesy of VOLKSWAGEN OF AMERICA, INC.
? Mount engine support bridge and adapter.
Fig. 55: Mounting Engine Support Bridge And Adapter Courtesy of VOLKSWAGEN OF AMERICA, INC.
CAUTION: Before installing the adapter hooks, disconnect all hoses and wiring in the vicinity of the engine lifting eyes, to prevent
damage.
? Tighten support bridge assembly and slightly lift engine/transmission assembly via spindles. ? Remove sound deadening pan below engine/transmission assembly.
? Remove starter, see STARTER MOTOR, REMOVING AND INSTALLING
NOTE: Before removing lower mounting bolts, first disconnect power steering hose at transmission.
? Remove front bracket.
? Disconnect axle shafts from axle flanges (both sides), turn steering all the way to the left, and tie axle shafts aside, as high as possible.
CAUTION: Take care not to damage surface protection.
? Remove support between transmission and engine (if applicable) by removing bolts -A- and -B-. ? Remove small clutch cover plate behind axle flange.
? Push engine/transmission assembly as far to the right as possible.

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5 SPD. MANUAL TRANSMISSION 02A (A3 PLATFORM) -1999 Volkswagen Jetta GL
Page 3 of 5
Fig. 56: Removing Support Between Transmission And Engine By Removing Bolts -A- And - B-
Courtesy of VOLKSWAGEN OF AMERICA, INC.
? Remove transmission mount -A- from transmission as described in the steps that follow: ? Using both engine support adapter spindles, lift engine/transmission assembly until exhaust system just contacts heat shield.
CAUTION: Take care not to damage brackets for operating cables.
Fig. 57: Removing Transmission Mount (-A-) From Transmission Courtesy of VOLKSWAGEN OF AMERICA, INC.
? Press engine/transmission assembly rearward toward bulkhead over pins -A-.
CAUTION: Take care not to damage brackets for operating cables.
Fig. 58: Pressing Engine/Transmission Assembly Rearward Toward Bulkhead Over Pins -A- Courtesy of VOLKSWAGEN OF AMERICA, INC.
? Remove lower mounting bolt -B-.
? Using both engine support adapter spindles, lower engine/transmission assembly back to previous position, then position at an angle using left spindle.
? Remove clutch cover plate.
? Remove bolt at engine/transmission mount above right axle flange.
? Assemble transmission jack with transmission support 3282 and 02A adjustment plate 3282/8 with holding elements, as follows: Fig. 59: Removing Lower Mounting Bolt -B- Courtesy of VOLKSWAGEN OF AMERICA, INC.
? Place 02A adjustment plate 3282/8 on transmission support 3282 (fits in one position only). ? Align arms of transmission support with holes in adjustment plate.
? Install holding elements -A- according to diagram on adjustment plate. ? Place transmission jack under vehicle.
? Arrow symbol -B- points forward, in vehicle driving direction
Fig. 60: Placing 02A Adjustment Plate 3282/8 On Transmission Support 3282 (Fits In One Position Only)
Courtesy of VOLKSWAGEN OF AMERICA, INC.
? Align adjustment plate parallel to transmission and position safety bracket against transmission.
NOTE: If transmission support 3282 is not available, the transmission can

1/4/2012
5 SPD. MANUAL TRANSMISSION 02A (A3 PLATFORM) -1999 Volkswagen Jetta GL
Page 4 of 5
be removed and installed using VAG 1383A transmission jack.
Fig. 61: Aligning Adjustment Plate Parallel To Transmission And Position Safety Bracket Against Transmission
Courtesy of VOLKSWAGEN OF AMERICA, INC.
? Remove lower engine/transmission mounting bolt.
? Press transmission off alignment sleeves and lower carefully, pushing engine slightly forward.
CAUTION: While lowering transmission avoid damaging power steering lines.
Installing

The transmission is installed in the reverse order of removal. In this process, install engine/transmission mounts so that they are free of tension. See ENGINE/TRANSMISSION MOUNTS, TIGHTENING
TORQUES.
NOTE: ? If the transmission is being replaced, transfer the Speedometer
Vehicle Speed Sensor (VSS) (G22), Back-Up Light Switch (F4) and relay lever from the old transmission to the new one.
Fig. 62: Identifying Speedometer Vehicle Speed Sensor (G22), Back-
Up Light Switch
Courtesy of VOLKSWAGEN OF AMERICA, INC.
? Before installing transmission, press clutch release lever toward
transmission case and secure with M8 x 35 bolt.
? Remove bolt once transmission is installed. Hole is then occupied by 3rd mounting bolt for operating cables bracket.
? Clean splines of main shaft and lubricate lightly with G 000 100 grease.
? When replacing the transmission, check for correct positioning of
intermediate plate.
? Check to make sure that engine/transmission alignment dowel
sleeves are in place in cylinder block. Replace if necessary.
Fig. 63: Pressing Clutch Release Lever Toward Transmission Case And Securing With M8 X 35 Bolt
Courtesy of VOLKSWAGEN OF AMERICA, INC.
Tightening sequence for support between engine and transmission (if applicable): ? Install all bolts and tighten by hand
? Tighten bolts -A- to 45 N.M (33 ft lb) ? Tighten bolts -B- to 45 N.M (33 ft lb)

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5 SPD. MANUAL TRANSMISSION 02A (A3 PLATFORM) -1999 Volkswagen Jetta GL
Page 5 of 5
? Check transmission oil level, see TRANSMISSION OIL LEVEL, CHECKING
? Adjust gear selector mechanism, see GEAR SELECTOR MECHANISM, ADJUSTING
Fig. 64: Identifying Tightening Sequence For Support Between Engine And Transmission Courtesy of VOLKSWAGEN OF AMERICA, INC.

1/4/2012

Rivermikerat
Jan 5, 2012.


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