Tape over the intake hose - this will create a good seal againstĭropped nuts and loose flying springs entering the intake tract. Don't open the intake box unless you are going to change theįilter because it will break the foam seal. Set the batteryĪside, don't bother putting it on wood since it doesn't make a difference inĭischarging. Remove the battery and air intake box/accordion hose. Sure the car is stable and secure on level, solid ground. You will be shaking the car a bit so make Using wood blocks gave me a little more clearance under theĬar for the transmission jack. Wood blocks for an additional support for the car. Mk4 Jetta jack points for the jack locations that were on my car and 1000q:
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Raise the front of the car and securely rest it on jack stands. Detailed stepsīelow, pics were taken at various steps for illustration. Support the engine, remove the transmission mount, and remove. VW engine support 10-222a/1 (equivalent support from harbor freight or northernģx horizontal transmission mount bolts: VW# n 104 062 02Ģx 18mm vertical mount bolts: VW# n 102 096 05Ģx subframe-dogbone mount bolts : VW# n 102 683 04 Procedure summary: there are 3 basic steps: remove the battery box, shifter cables, starter, clutch slave cylinder,Īnd 2 sensors. Transmission jack (optional but suggested) Insist on double checking the sealĭimensions if you order a seal at the local parts store! The seal is 62mm outer diameter, 48mm Parts (click links to compare current prices)Ĩmm triple square (12 point) bit for the driveaxle bolts, see metalnerdġ2 point 9mm and 10mm sockets (optional, for the clutch and flywheel replacement)Ĥ09 189 b *Caution - this is the same part number as mk3 transmissionsĪnd I found that Napa, Autozone, and Carquest all use the same incorrect spec in I don't suggest buying replacement axlesĭespite their low price just for the new boot because genuine VW axles areīetter quality and better balanced than most of the axles you'll find at the It's also a good time to replace the CV boots if Observe all cautions in the factory service manual and see the TOS Agreement for theĪn engine support is required because you will be removing the transmission Manual, refer to your factory service manual for the official instructions. This article is not a substitute for the factory service This would be a good time to do it, see 1000q:ĥth gear swap for more details. Replace the 5th gear with a taller gear to improve mileage and lower rpms/noise, Remove the transmission if you want to replace the rear main oil seal, see 1000q: Over the years such as oil seals so verify all part numbers with your There may be small changes to the part numbers Mk4 Jetta Golf New Beetle TDI with ALH engine.ĭifferent gearing from the Jetta and Golf. Introduction This article has tips on how to remove and replace the manual transmission in the > Dismantling and assembling gearbox selector mechanism from 05.Transmission removal on mk4 Jetta Golf New Beetle ALH TDI engine Transmission removal on mk4 VW Jetta TDI, also Golf and New Beetle TDI Power transmission > 5-speed manual gearbox 02J > Gearbox mechanics,operation, construction,diff. Selector shaft is locked into cover by inserting a spring clip -B- through one of the grooves -A-, with a forward gear engaged. The spring clip -B- is inserted in the cover. Revised selector shaft and selector coverįrom gearbox build date 06 08 1 the selector shaft is equipped with four grooves -A. When shifting down from 5th gear to 4th gear the bolt -2- guides the selector shaft over bridge -3- into 4th gear gate. In conjunction with this the stop sleeve is fitted with a bridge -3. Revised selector cover and selector shaftĪs of gearbox build date 04 09 0 bolt -2- is installed in selector cover -1. Knocking ball sleeve into selector mechanism cover ‒ Before pulling out ball sleeve, destroy plastic cage and remove balls.Ī - Internal extractor, e.g.Removing ball sleeve from selector mechanism cover ◆ From gearbox build date 06 08 1 with locking mechanism for the selector shaft => Fig.◆ Can be replaced with the selector mechanism installed.◆ Install so that the master spline aligns with selector shaft.◆ With an additional bolt which allows the selector shaft to be guided into the 4th gear gate when changing down from 5th to 4th gear, have been introduced as of gearbox build date 04 09 0 => Fig.◆ From gearbox build date 06 08 1 additional locking mechanism in end cover =>Fig.◆ Revised stop sleeves, which allows the selector shaft to be guided into the 4th gear gate when changing down from 5th to 4th gear, have been introduced as of gearbox build date 04 09 0 =>Fig.Special tools and workshop equipment required Special tools, workshop equipment, test and measuring appliances and auxiliary items required
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Dismantling and assembling gearbox selector mechanism from 05.99