Mk3 Golf 1.9 TD Gearbox Removal

[tsam19]

Hi

I'm asking if anyone can advise me on the best way to remove a gearbox from my car as it has developed a fault (ie the Diff rivets) & needs to come off for the gearbox to be stripped.

Is there any do's & don'ts, what tools & equipment would I need ?

I am willing to have a go at this myself as I class myself as being more than capable. just never done it before.

If anyone has any weblinks showing how this can be done or with picture instructions that is great.
Thankyou.

[gldgti]

hey mate - basically it goes like this -

> support the car on axel stands unde the rear side of the subframe, allowing the wheels to hang free.
> d/c clutch cable and electrical wiring from box
> disconnect driveshafts from gearbox and tie (with cable ties) out of the way (up)
> use a trolley jack to support the engine with a block of wood under the sump
> remove starter motor
> remove front engine mount (bolts on with starter motor bolts)
> remove front crossmember
> use an engine crane to support the weight of the gearbox through the lifting lug cast into the main gearbox casing. not many people realise that the gearbox balances perfectly here.
> remove gearbox mount and linkages
> remove bolts retaining geabox to engine block.

I think thats everything. once all that is done, push the clutch lever up to release the gearbox from the clutch assy and man-handle the gearbox off the engine. it is necessary to lower the engine with the trolley jack a bit to get some extra clearance.

i have found that you usually need to rotate the end of the gearbox down to almost 90degrees to get it free from the flywheel assy, once puled sufficiently far out from the engine. then the gearbox may be safely lowered to the ground using the crane.

its helpful (but not necessary) to have a friend to help. especially to get the crane and or jack to go up and down as necessary.

i think thats it. good luck!

BTW - welcome to VWW. its good to have another turbo-dieseler around. where are you from?

PS - this procedure applies to all 020 gearboxed mk3's.