Removal And Installation: Transmission: Installing

NOTE:

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

Replace the self-locking nuts and bolts.

Replace bolts that are have been tightened to an angle torque.

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

Clean the input shaft splines -1- and the hub splines (in the case of a used clutch disc). Remove any corrosion and then apply a very thin coat 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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- 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 installed on the adjustment plate 3282/33.

Fig 2: Installing Support Elements Onto Adjustment Plate

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- 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.

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

Fig 3: Inserting Engine/Transmission Connecting Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- 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. Pay close attention to the steering gear.

NOTE:

Pay attention to the lines when installing the transmission.

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

-- Align the transmission with respect to the engine and install it.

-- Install the engine/transmission bolt -C- and tighten it to specification. Refer to Transmission To Engine Bolt Tightening Specifications .

Fig 4: Inserting Engine/Transmission Connecting Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Install the lower engine/transmission bolts and tighten them to specification. Refer to Transmission To Engine Bolt 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 Bolt 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 5: Inserting Actuator Lever Into Shift Mechanism And Clip In Locking Washer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Install the relay lever -1- and lock washer -arrow- to the gear shift unit.

With a Plastic Relay Lever:

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

Continuation for all Vehicles:

Fig 6: Installing Console With New Hex Bolts On To Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Install the transmission mount bracket -1- with new bolts -arrows- to the transmission and tighten them to specification. Refer to Transmission To Engine Bolt Tightening Specifications .

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

Fig 7: Aligning Engine/Transmission In Installed Location

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Install the new bolts -arrows- fro the transmission mount -2- to the transmission mount bracket -1- and tighten them to specification. Refer to Transmission To Engine Bolt 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 engine/transmission bolt -arrow- and tighten it to specification. Refer to Transmission To Engine Bolt Tightening Specifications .

Fig 8: Removing/Installing Small Cover Plate For Flywheel

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Install the small flywheel cover plate -A- and tighten the bolt to specification. Refer to Transmission To Engine Bolt Tightening Specifications .

Fig 9: Guiding Right Flange Shaft In Area Of Flywheel/Intermediate Plate

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Install right drive axle directly to the flange shaft of the transmission. Refer to Removal and Installation .

-- Install the drive axle heat shield and bolts -arrows-, if equipped. Refer to Specifications .

Fig 10: Drive Axle Heat Shield Bolts And Shield

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 11: Identifying First Thread

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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

Fig 12: Transmission Pendulum Support

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Install the left drive axle to the transmission flange shaft. Refer to Removal and Installation .

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

Fig 13: Left Front Level Control System Sensor

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Assemble the exhaust system and then attach it to the subframe. Refer to [For engine(s) BPY] Removal and Installation [For engine(s) CCTA, CBFA] Removal and Installation .

-- Install the exhaust system support -1- (if equipped) to the transmission -arrow- and to the front exhaust pipe.

Fig 14: Identifying Exhaust System Brace

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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

Fig 15: Identifying Ground Strap & Back-Up Light Switch F4 Electrical Harness Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- 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 16: Clamping Off Hose/Line Assembly Hose To Slave Cylinder With Hose Clamps

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- 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 and supply hose.

-- After removing the hose clamps up to 25 mm dia. 3094, bring the 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 item 10.

Fig 17: Removing/Installing Cable Mounting Bracket From Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 18: Removing/Installing Shift Cable Lock Washer From Transmission Shift Lever And Cable From Pins

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- 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:

-- Install 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 [For engine(s) BPY] Removal and Installation [For engine(s) CCTA, CBFA] Removal and Installation .

-- Install the foam pieces on the left and right fender upper edges. Refer to Description and Operation .

-- Install the engine cover if necessary.

-- Connect the battery and 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 FRONT WHEEL HOUSING LINER .

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

-- Install the wheels. Refer to WHEEL, CHANGING AND MOUNTING .

-- 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 19: Transmission To Engine Bolt Tightening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Transmission To Engine Bolt 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 for centering

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

Transmission Mount Bracket to Transmission

Fig 20: Installing Console With New Hex Bolts On To Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Replace the transmission mount -1- to transmission bolts -arrows-.

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

Transmission Mount to Transmission Mount Bracket

Fig 21: Aligning Engine/Transmission In Installed Location

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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

NOTE:

Install the engine/transmission mount free of tension. Refer to [For engine(s) CCTA, CBFA] Description and Operation .