Removing and Installing Central Tube
RemovingNote: When performing operations on the transaxle system that involve rotating or shifting the transaxle tube, always wear leather gloves to avoid injuries.
1. Take off rear wheels.
2. Disconnect battery ground lead.
3. Disconnect parking brake cable on parking brake lever and pull back out of guide.
4. Loosen control cable on bracket and disconnect on accelerator pedal.
5. Press control cable out of rubber guide in firewall and pull out cable forward.
Disconnect suspension clamps on engine and front bell housing.
6. Remove splash shield.
7. Remove entire exhaust assembly.
8. Disconnect axle shafts on transmission end and remove rear axle.
9. Disconnect selector lever cable on transmission after removing lockpin for ball socket.
10. Loosen mounting clamps for starter wires on front bell housing and remove starter.
Note: Suspend starter from suitable point on car so that the wire harness is not stretched.
11. Disconnect holder for ATF lines on camshaft housing.
12. Disconnect ATF lines between firewall and engine.
13. Remove ground wire on clutch bell housing.
Note: Since the heater valve covers up the ground point, the coolant must be drained partially and the valve removed.
14. Unscrew screws for speed and reference mark transmitters. Pull out transmitters while turning back and forth at same time.
15. Unscrew clamp screw.
16. Mark position of flywheel/damper for reinstallation later or turn flywheel until marks in starter opening are visible.
17. Unscrew damper mounting bolts (if necessary, hold tight on pulley bolt) and press damper off of flywheel.
18. Position universal transmission jack underneath transmission and mount retaining strap.
A = Wooden block
19. Unscrew mounting bolts for transmission suspension on transmission carrier.
20. Remove center and rear cross members. Hold engine in installed position with VW 10-222.
21. Unscrew bolts on engine block/front bell housing flange.
22. Pull back transmission with central tube.
23. Remove front cross member and lower central tube with transmission carefully without stretching or bending the control cable.
Note: This step requires an extra person on the front bell housing to balance the weight of the central tube for safety's sake.
Installing
Note: Installation marks (not TDC mark) on flywheel and damper must be aligned. Before installing the central tube, turn flywheel and damper until installation marks face down at an angle (toward starter opening).
1. Wrap pieces of adhesive tape around insulation sheet and coat mating surfaces for body with an assembly paste (e.g. rubber lubricant) to facilitate installation.
A = Adhesive tape
2. Install speed and reference mark transmitters.
Note: Transmitters have permanent magnets. Make sure metal particles are not stuck on the transmitters before installing.Note marks of transmitters. Never use force to install them.Tighten transmitters mounting screws to 8Nm (6ftlb) torque.
3. Install rubber grommet between selector lever cable and suspension console.
4. Adjust selector lever and control cables (see Shift Cable,A/T).