Volkswagen Jetta, Golf User Manual

Jetta / Golf 020 Transmission

Replacement and Clutch Installation

developing problems. If there is one thing you should learn from reading

is unnecessary.

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of 15Jetta / Golf 020 Transmission Replacement and Clutch Installation

3/12/2008

http://www.copperli.lrehosting.com/transmission/Jetta%20tranny.htm

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Welcome to the 020 tranny replacement brought to you by tiohero. This page is in NO WAY meant to be a DIY or any
type of instructional resource. If you read the following I do not take any responsibility for any and all actions which
cause harm or damage to you or your vehicle. If you are planning on installing a new clutch and/or replacing the
tranny, I highly recommend that you only use the directions stated in the Bentley service manual available here:

http://www.amazon.com/exec/obidos/tg/detail/-/083760365X/qid=1112340637/sr=1-1/ref=sr_1_1/102-2399138­9852168?v=glance&s=books

BTW: some of these pictures are THUMBNAILS... click for large

pics

The reverse gear in my 020 tranny was completely shot. Ever since I bought my car the reverse gear made all sorts of
noise when backing up. Approx 10K miles later I lost reverse gear and the car would barely shift into 2nd anymore. I
was fortunate considering many people lose every grear along with losing reverse. In my opinion the 020 transmission
is a crappy design and it is extremely prone to
this you should know to always shift into 1st gear in order to stop the tranny from spinning, AND THEN shift into
reverse. This way you will not chip the reverse gear and you will get lots of life out of it.While doing this installation, I
was fortunate enough to have the old tranny spill its fluid all over the garage floor. What's interresting is that the fluid
was BLACK (with 83K miles on the old tranny)... keep in mind that the user's manual tells you that changing the fluid

doesn't work like it used to

cable...

www.germanautoparts.com

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of 15Jetta / Golf 020 Transmission Replacement and Clutch Installation

3/12/2008

http://www.copperli.lrehosting.com/transmission/Jetta%20tranny.htm

Step 1: I needed a new tranny for my car, but in this case a used/rebuilt tranny will make do. It just so happened there
was an extra one in the trunk of my car.

Step 2: Unhook the negative battery terminal.

Step 3: Here is the "auto adjust clutch cable." I used some wire to completely compress the cable and hold it solid like
that. BTW: These things are great when they work, but when the clutch wears out, the cable
anymore. You may notice that the clutch starts "grabbing at the top." Best thing to do is to get a manual adjust clutch

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of 15Jetta / Golf 020 Transmission Replacement and Clutch Installation

3/12/2008

http://www.copperli.lrehosting.com/transmission/Jetta%20tranny.htm

Step 4: With the clutch cable compressed, unhook the base of the clutch cable from the tranny. At this point I grabbed
some index cards and laid them down on a table in order to label and sort every nut, bult, etc. that came out of the car.

Step 5: Unhook the clutch cable from the top of the tranny.

Step 6: Here is the ground strap on the top of the tranny belhousing... notice how it is corroded. You will need to

used "crow

foot wrenches" (pitured above) and reefed hard on that bolt till I

was afraid to snap it off. I gave up and decided to take

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of 15Jetta / Golf 020 Transmission Replacement and Clutch Installation

3/12/2008

http://www.copperli.lrehosting.com/transmission/Jetta%20tranny.htm

remove this wire and then sand down and clean up the contacts before you place it back on again later (after the re­installation). This way you will not have all sorts of electrical problems such as your alarm going off randomly every 5
minutes.

Here it is again with the wire and bolt removed... beautiful!

Step 7: Here you can see I have disconnected the two wiring harnesses for the oxygen sensors and moved them out of
the way (makes things MUCH easier). Under the O2 sensor harnesses you can see a large bolt which holds the metal
O2 sensor bracket on the engine mount. I had to remove that bolt... underneath there is another bolt...

Step 8: The Bentley says to remove this engine mount bolt to remove the engine mount... haha, good luck! I

a different approach to removing that engine mount (think outside the box)...

Some grinding...

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of 15Jetta / Golf 020 Transmission Replacement and Clutch Installation

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http://www.copperli.lrehosting.com/transmission/Jetta%20tranny.htm

Step 9: Here is a view of the underside of the same engine mount. I was able to easily remove the bolts that hold the
engine mount directly to the engine... problem solved.

Step 10: I needed to remove more engine/tranny mounts which meant that some kind of engine support was necessary.

So of course I went down to the VW dealership and purchased VW special tool # 10-222A. Just kidding! ....