Transmission, Installing

NOTE:

Before installing transmission press clutch release lever toward transmission housing and secure with assembly pin, assembly bolt or M 8 x 35 bolt. Remove after transmission has been installed. The hole will then be sealed by the 3rd cable support bracket securing bolt or plugged.

Fig 1: Identifying Clutch Release Lever And Bolt

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NOTE:

When replacing transmission, the sensors for speedometer (Fig.), gear selector and relay lever must be transferred to new assembly.

Fig 2: Identifying Sensor For Speedometer

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-- Clean input shaft splines and lightly grease with grease G000 100.

Clutch plate must be able to slide lightly back and forth on input shaft.

-- Check whether dowel sleeves for aligning engine and transmission are installed in cylinder block, install if necessary.

-- Make sure that intermediate plate is correctly positioned on engine.

-- Bolt support rail VW 457/1 to both pendulum support securing holes on subframe.

Fig 3: Identifying Support 3300 A, Support Rail VW 457/1 & Hex Bolts

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-- Spacers totaling 6 mm must be inserted between subframe and support rail VW 457/1.

-A- Qty. 2 hex bolts M 8 x 25

NOTE:

Mounting rail T10036 can be used instead of mounting rail VW 457/1.

-- Install support 3300 and secure -arrows-.

1.8L Engine

Fig 4: Identifying Support 3300 A

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The support 3300 must sit on the threaded boss on the engine.

Continuation for All Vehicles

-- Press engine forward carefully.

NOTE:

Do not damage power steering line.

-- Assemble transmission jack with Transmission support 3282, Adjustment plate 3282/8 for "02A" transmission and support elements as follows:

-- Place Adjustment plate 3282/8 on Transmission support 3282. (Adjustment plate only installs in one position).

-- Align arms of transmission support according to holes in adjustment plate.

-- Install mounting element -A-, as illustrated on alignment plate.

Fig 5: Identifying Support Elements & Symbol On Adjustment Plate

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-- Install transmission on transmission jack.

-- Align adjustment plate and transmission parallel with one another and lock safety supports on transmission.

-- Position transmission jack under vehicle, -arrow- symbol -B- (illustration above) on alignment plate faces toward front of vehicle.

Fig 6: Identifying Transmission Jack Positioned Under Vehicle

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-- Align transmission to engine.

NOTE:

Do not damage power steering line.

-- Install lower engine and transmission securing bolts.

-- Remove support 3300A -arrows-.

Fig 7: Identifying Support 3300 A, Support Rail VW 457/1 & Hex Bolts

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-- Remove bolts -A- and remove support rail VW 457/1.

-- Install upper engine and transmission securing bolts.

-- Install transmission console -A- with new bolts -arrows-.

Fig 8: Identifying Transmission Mount

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-- Align engine and transmission in installation position.

-- Install new hex bolts -arrows B- for left hand assembly mounting in transmission mounting.

Fig 9: Identifying Transmission Support & Hex Bolts

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-- Install transmission support -arrows A- to transmission.

CAUTION:

Do not remove support bar 10-222A until the bolts securing the left-hand transmission mount have been tightened to torque setting.

-- Install lower engine and transmission securing bolt -arrow A-.

Fig 10: Identifying Pendulum Support & Engine/Transmission Securing Bolt

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-- Install pendulum support -arrows-.

-- Use new bolts for securing.

-- Reconnect exhaust system.

-- Install retainer for power-assist steering line on starter and on transmission.

-- If it was removed install small cover plate -A- behind right-hand drive flange -arrows-.

Fig 11: Identifying Cover Plate & Right-Hand Drive Flange

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-- Install drive shafts to transmission.

-- If it was removed install protective cap for right-hand inner constant velocity joint to engine.

-- Install starter. Removal and Installation

-- Install slave cylinder

Fig 12: Identifying Slave Cylinder Fasteners

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Vehicles through 05.99

-- Install cable support bracket on transmission -arrows-, if necessary push hose onto cable support bracket.

Fig 13: Identifying Cable Support Bracket Bolts

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-- Install gear selector cable -B- and balance weight -A- on gear selector lever.

Fig 14: Identifying Balance Weight, Gear Selector Cable & Actuating Arm/Relay Lever

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-- Install gate selector cable on follower/relay lever -C- to do this lift lug in direction of -arrow-.

Vehicles from 06.99

-- Install cable support bracket to transmission -arrows-, press hose -A- on to cable support bracket.

Fig 15: Identifying Cable Support Bracket At Transmission

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-- Install gear selector cable -B- with transmission selector lever -arrow-.

Fig 16: Identifying Gate Selector Cable, Gear Selector Cable & Nut

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-- Install gate selector cable -A- with relay lever and secure -arrow-.

Continuation for All Vehicles

-- Attach back-up light connector -arrow 2-. Attach all other electrical connections and ground wires to transmission and to engine and transmission securing bolts.

Fig 17: Identifying Speedometer Sensor & Reverse Light Connectors (Up To 05.99)

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-- Attach connector to speedometer sensor -arrow 1-.

-- Adjust gear change mechanism GEAR SELECTOR MECHANISM, ADJUSTING .

-- Assemble air intake duct. AIR FILTER ASSEMBLY OVERVIEW

-- Install battery carrier.

-- Install battery.

-- Reconnect Ground (GND) cable to battery.

NOTE:

Note radio coding for vehicles with coded radio.

-- Install power steering reservoir on to battery carrier.

-- Check transmission oil TRANSMISSION OIL, CHECKING .

-- Install engine cover.

-- Install noise insulation tray.