Removal And Installation: Transmission: Installing

NOTE:

Refer to TRANSMISSION to get a list of the special tools needed.

Replace the self-locking nuts and bolts.

Replace bolts that have been tightened to a torque angle.

Reinstall cable ties that were loosened or cut off during removal at the same locations during installation.

Clean the input shaft splines and (on used clutch discs) the hub splines. Remove any corrosion and apply a very thin coating of grease for clutch plate splines G 000 100 on the splines. Then move the clutch disc back and forth on the input shaft until the hub moves freely on the shaft. Excess grease must be removed.

-- If the transmission is replaced, transfer the transmission shift lever and the relay lever.

-- Clean all threaded holes for self-locking bolts with a thread tap to remove any locking fluid residue.

-- Check whether there are alignment sleeves for the engine/transmission in the cylinder block; install if necessary.

If the alignment sleeves are missing, it will be difficult to shift, there will be clutch problems and the transmission may make noises (loose rattling).

-- Make sure the intermediate plate is engaged on the sealing flange and pushed onto the alignment sleeves -arrows-.

Fig 1: Identifying Intermediate Plate Alignment Bushings

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-- Check the release bearing for wear. If necessary, replace the slave cylinder and the release bearing. Refer to SLAVE CYLINDER WITH RELEASE BEARING .

To install the transmission, the transmission support 3282 must be equipped with the adjustment plate 3282/33.

Fig 2: Installing Support Elements Onto Adjustment Plate

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-- Align the arms of the transmission support so that they match up with the holes in the adjustment plate.

-- Install the support elements -A- as illustrated on the adjustment plate.

-- Install the pins 3282/29 in place on the adjustment plate -C-.

-- Place the transmission on the engine/transmission jack V.A.G 1383 A.

-- Align the adjustment plate so that it is parallel to the transmission.

-- Install the pin 3282/29 into the hole on the transmission for the pendulum support bolt.

-- Secure the adapter VW 771/40 in the threaded hole in the transmission housing as illustrated.

Fig 3: Inserting Engine/Transmission Connecting Bolt

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-- Secure the transmission on the transmission support 3282 using the bolt -A-.

The arm -B- must be flush -arrow- with the guide on the transmission support 3282.

-- Place the engine/transmission jack V.A.G 1383 A under the vehicle. The arrow points in the direction of travel.

-- Using the spindles on the transmission support 3282, adjust the transmission so that the differential area is rotated upward.

-- Carefully lift the transmission while paying attention to the steering gear -3-.

Fig 4: Identifying Electro-Mechanical Steering Gear, Flange Shaft & Bolt-On Eyelet

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NOTE:

Pay attention to the lines when installing the transmission.

The right flange shaft -1- must be guided over the bolting eyelet of the engine -2-.

-- Turn the transmission into its installed position using the spindles on the transmission support 3282.

-- Line up the transmission and the engine and install it.

-- Install the engine/transmission bolt -C- and tighten it to specification. Refer to TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS .

Fig 5: Inserting Engine/Transmission Connecting Bolt

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-- Install the engine/transmission bolt -arrow- and tighten it to specification. Refer to TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS .

Fig 6: Removing/Installing Engine/Transmission Connecting Bolt

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-- Install the lower engine/transmission bolts and tighten them to specification. Refer to TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS .

-- After the transmission is bolted to the engine at the bottom, remove the transmission support 3282 from the transmission.

-- Install the upper engine/transmission bolts and tighten them to specification. Refer to TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS .

-- Attach the transmission shift lever to the gear shift unit, refer to Figure and then tighten the nut to specification, see item 17.

With a Metal Relay Lever:

Fig 7: Inserting Actuator Lever Into Shift Mechanism And Clip In Locking Washer

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-- Install the relay lever -1- in the transmission shift lever and the lock washer -arrow-.

With a Plastic Relay Lever:

-- Install the relay lever with the cable retainer. Refer to PLASTIC RELAY LEVER .

Continuation for all Vehicles:

-- Install the transmission mount bracket -1- with the new bolts -arrows- to the transmission and tighten them to specification. Refer to TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS .

Fig 8: Installing Console With New Hex Bolts On To Transmission

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-- Align the engine/transmission in its installed position. Lift it until the bracket -1- is in complete contact with the transmission mount -2-.

Fig 9: Aligning Engine/Transmission In Installed Location

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-- Install the new bolts -arrows- for the transmission mount -2- to the bracket -1- and tighten them to specification. Refer to TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS .

WARNING:

Only remove the engine support bridge 10-222 A when all the transmission mount/bracket bolts are tightened to specification.

-- Install the small cover plate -A- for the flywheel behind the right flange shaft.

Fig 10: Identifying Small Cover Plate & Coolant Pipes

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-- Attach the coolant pipes -B- to the engine -arrows- if they were removed earlier. Refer to FRONT COOLANT PIPES and SMALL COOLANT PIPE . .

-- Install the subframe/control arm and pendulum support. Refer to Removal and Installation .

NOTE:

The holes for the pendulum support in transmissions from 28 May 2007 have threaded inserts (for example a "HeliCoil").

To recognize this: there is a collar on the first thread -arrow-.

Fig 11: Identifying First Thread

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Be sure to use the correct bolts and tightening specification. Refer to Description and Operation .

-- Install the pendulum support to the transmission. Refer to Installing .

Fig 12: Transmission Pendulum Support

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-- Install the drive axles to the transmission. Refer to Removal and Installation .

Fig 13: Drive Axle Heat Shield Bolts And Shield

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-- Install the drive axle heat shield and bolts -arrow-, if equipped. Refer to DRIVE AXLE HEAT SHIELDS .

-- Install the left front level control system sensor -G78-, if equipped. Refer to Removal and Installation .

Fig 14: Left Front Level Control System Sensor

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-- Install the exhaust system and then attach the suspended mount to the subframe. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .

-- Attach the exhaust system support -1- (if equipped) to the transmission -arrow- and to the front exhaust pipe. Refer to EXHAUST SYSTEM, INSTALLING .

Fig 15: Identifying Exhaust System Brace

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-- Install the charge air hose. Refer to CHARGE AIR HOSE, INSTALLING .

-- Install the starter and tighten the lower bolt. Refer to Removal and Installation .

-- Attach the bracket for the lines to the lower starter bolt.

-- Install the top bolt for the starter and attach the connectors and the cables to the starter. Refer to Removal and Installation .

Fig 16: Identifying Ground Strap & Back-Up Light Switch F4 Electrical Harness Connector

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-- Attach the ground strap -1- to the starter upper stud.

-- Connect the connector -2- to the backup lamp switch -F4-.

-- Push the hose/line assembly or pipe -A- into the breather assembly/slave cylinder to the stop and push the clip -arrow- downward.

Fig 17: Clamping Off Hose/Line Assembly Hose To Slave Cylinder With Hose Clamps

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-- Pull on the line to make sure it is secure.

-- Remove the hose clamps up to 25 mm dia. 3094 from the hose/line assembly or supply hose.

-- After removing the hose clamps up to 25 mm dia. 3094, bring the supply hose back to its original shape.

-- Bleed the clutch system. Refer to CLUTCH SYSTEM, BLEEDING .

-- Make sure the vacuum hose for the brake system is installed correctly.

-- Install the cable bracket to the transmission and tighten the bolts -arrows- (or nuts) to specification, see item 6 or items 10.

Fig 18: Removing/Installing Cable Mounting Bracket From Transmission

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-- Apply a small amount of grease to the pin -arrow- on the transmission shift lever -1-.

Fig 19: Removing/Installing Shift Cable Lock Washer From Transmission Shift Lever And Cable From Pins

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-- Replace the lock washer -3- after every disassembly.

With a Metal Relay Lever:

-- Apply a small amount of grease to the pin -arrow- on the relay lever -2-.

-- Slide the selector cable onto the pin -arrow- and secure with the lock washer -4-.

With a Plastic Relay Lever:

-- Insert the selector cable into the cable retainer.

Continuation for all Vehicles:

-- Adjust the shift mechanism. Refer to SHIFT MECHANISM, ADJUSTING .

-- Install the battery tray and the battery. Refer to Removal and Installation .

-- If removed, install the air filter housing. Refer to AIR FILTER HOUSING .

-- Install the foam pieces to the upper edges of the left and right fenders. Refer to Description and Operation .

-- Install the engine cover if necessary.

-- Connect the battery and then complete the steps after connecting the battery. Refer to Removal and Installation .

-- Check the transmission fluid level. Refer to TRANSMISSION FLUID, CHECKING .

-- Install the lower section of the left front wheel housing liner. Refer to Removal and Installation .

-- Install the noise insulation. Refer to Description and Operation .

-- Install the wheels. Refer to REMOVAL AND INSTALLATION .

-- Check the headlamp adjustment on vehicles with a left front level control system sensor. Refer to Diagnosis and Testing .

Tightening Specifications

Transmission to Engine

Fig 20: Transmission To Engine Bolt Tightening Sequence

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TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS

Item	Bolt	Quantity	Nm
1	M12 x 55 With a short M8 threaded pin	1	80
2	M12 x 55 With a long M8 threaded pin	1	80
3	M12 x 70	1	80
4	M10 x 50	2	40
5	M10 x 105	1	40
6	M12 x 165 With a short M8 threaded pin Also starter to transmission	1	80
7	M12 x 165 With a short M8 threaded pin Also starter to transmission	1	80
-	M6 x 8 Small flywheel cover plate (not present on all engines)	1	10

-A and B- : alignment sleeves

-- Replace the bolts -1 through 7-.

Small cover plate for flywheel to intermediate plate: 10 Nm.

Transmission Mount Bracket to Transmission

Fig 21: Installing Console With New Hex Bolts On To Transmission

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-- Replace the transmission mount bracket to transmission bolts -arrows-.

Tighten the bolts to 60 Nm + 90° (1/4) additional turn

Transmission Mount to Transmission Mount Bracket

Fig 22: Aligning Engine/Transmission In Installed Location

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-- Replace the transmission mount to transmission mount bracket bolts -arrows-.

Tighten the bolts to 60 Nm + 90° (1/4) additional turn

NOTE:

Install the engine/transmission mount free of tension. Refer to ENGINE, INSTALLING .