Transmission, Installing

-- Clean any locking compound residue from all threaded holes using a tap.

-- Replace self-locking screws and nuts after removing them.

-- Make sure the alignment sleeves for centering the engine/transmission are installed inside the cylinder block. Install them 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 is pushed onto the alignment sleeves -arrows-.

-- Clean the drive axle splines and grease lightly with Grease For Clutch Disc Shaft Splines G 000 100.

It must be possible to slide the clutch plate back and forth on the input shaft.

-- Check the clutch release bearing for wear. Replace the clutch slave cylinder with release bearing if necessary, refer to CLUTCH SLAVE CYLINDER WITH RELEASE BEARING, REMOVING AND INSTALLING .

Align the Transmission Support 3282 with the Transmission Support - Mounting Plate 333282/33 in order to install the "02Q" transmission.

-- 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 shown on the Adjustment Plate.

-- Install the Mounting Element -C- instead of the Transmission Support - Pins 293282/29.

-- Place the transmission on the Engine and Gearbox Jack VAS6931.

-- Align the Adjustment Plate so that it is parallel to the transmission.

-- Install the Transmission Support - Mounting Plate 293282/29 into the rear hole in the transmission for the pendulum support bolt.

-- Secure the Slide Hammer Set - Adapter 40 VW771/40 inside the threaded hole in the transmission housing as shown.

-- Secure the transmission on the Transmission Support 3282 with an M10 x 20 bolt -A-.

The needle bearing drift -B- must be flush with the guide on the Transmission Support 3282 -arrow-.

-- Position the Engine and Gearbox Jack VAS6931 under the vehicle. The arrow on the adjusting plate points in direction of travel.

-- Lift the transmission carefully.

• The right flange shaft must be guided past the flywheel -arrow 2- ; pay attention to the intermediate plate -arrow 1-.
  Fig 4: Identifying Right Flange Shaft Guided Past Flywheel

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- At the same time, change the position of the transmission using the spindles of the Transmission Support 3282 so that it does not come into contact with the longitudinal member -arrows-.

-- Turn the transmission into it installed position using the spindles on the Transmission Support 3282.

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

-- Insert engine/transmission bolt -C- and tighten to tightening specification, refer to TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS .

-- Install lower engine/transmission connecting bolts and tighten to tightening specification, refer to TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS .

-- Install the engine/transmission connecting bolt -arrow- and tighten it to the tightening specification, refer to TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS .

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

-- Install the upper engine/transmission connecting bolts and tighten them to the tightening specification, refer to TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS .

-- Attach the selector lever to the transmission gearshift shaft, refer to Figure and tighten the nut to the tightening specification, refer to OVERVIEW - OPERATING CABLES .

-- Install the relay lever and cable retainer -arrow 2- all the way into the gearshift cover.

-- Install the clip -arrow 1- and make sure it is locked into place.

-- Attach the transmission bracket -1- with the new bolts to the transmission -arrows- and tighten them to the tightening specification, refer to OVERVIEW - SUBFRAME MOUNT .

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

-- Install the new bolts -arrows- on the left subframe mount -2- in the transmission bracket -1- and tighten them to the tightening specification, refer to OVERVIEW - SUBFRAME MOUNT .

-- Attach the drive axles to the transmission, refer to [For engine(s) CDVB, CPRA, CBTA, CPKA, CKRA, CBUA] Drive Axle Overview .

-- Install the heat shield (if equipped) over the right drive axle, refer to [For engine(s) CDVB, CPRA, CBTA, CPKA, CKRA, CBUA] Drive Axle Overview .

-- Install the subframe and steering gear, refer to [For engine(s) CDVB, CPRA, CBTA, CPKA, CKRA, CBUA] Subframe Overview .

-- Install the pendulum support with new bolts .

-- Assemble exhaust system and fasten exhaust system bracket to subframe, refer to [For engine(s) CKRA] Exhaust System, Emission Controls or [For engine(s) CVCA] Exhaust System, Emission Controls or [For engine(s) CPRA, CPKA] Exhaust System .

-- Position the starter and install the lower bolt, refer to [For engine(s) CVCA, CDVB, CPRA, CBTA, CPKA, CKRA, CBUA] Starter .

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

-- Install the starter bolt and then connect the connector and wires to the starter, refer to [For engine(s) CVCA, CDVB, CPRA, CBTA, CPKA, CKRA, CBUA] Starter .

-- Attach the ground strap -1- to the top starter bolt.

-- Connect the connector -2- to the Back-Up Lamp Switch -F4-.

-- Transmission on vehicles with Start/Stop System: connect the connector -arrow- to the Transmission Neutral Position Sensor -G701-.

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

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

-- Remove the Hose Clamps - Up To 25 mm 3094 from the hose/line assembly or supply hose.

-- Bend the supply hose back into its original shape after removing the Hose Clamps - Up To 25 mm 3094.

-- Bleed the clutch mechanism, refer to CLUTCH MECHANISM, BLEEDING .

-- Make sure the vacuum hose for the brake system is installed correctly. Install a vacuum hose, if necessary, refer to Brake Fluid .

-- Attach the cable mounting bracket to the transmission and tighten the bolts and nuts -arrows- to the tightening specification -item  19 and -item  8-.

-- Apply a small amount of Grease on the pin -arrow- on the gearshift lever -1-.

• Grease allocation.

-- Secure the shift cable -2- to the gearshift lever with a new lock washer -3-.

-- Install the selector cable into the cable retainer on the relay lever.

-- Adjust the gearshift mechanism, refer to SELECTOR MECHANISM, ADJUSTING .

-- Install the plenum chamber cover, refer to Bulkhead .

-- Tighten the left and right lock carrier bolts -arrows- for the carrier, refer to Lock Carrier .

-- Install the battery tray and the battery, refer to Battery with Visual Indicator, Standard .

-- Install the crankcase ventilation hose and the air guide hose on the turbocharger, refer to [For engine(s) CPRA, CPKA] Engine, Removing and Installing or [For engine(s) CKRA] Engine Assembly or [For engine(s) CVCA] Engine Assembly .

-- Install the air filter housing, refer to [For engine(s) CKRA] Air Filter Housing Overview or [For engine(s) CVCA] Air Filter Housing, Removing and Installing .

-- Install the engine cover, refer to [For engine(s) CPRA, CPKA] Engine, Removing and Installing or [For engine(s) CKRA] Engine Assembly or [For engine(s) CVCA] Engine Assembly .

-- Connect the battery and follow the procedure regarding what to do after connecting a battery, refer to Battery with Visual Indicator, Standard .

-- Check transmission fluid level, refer to TRANSMISSION FLUID LEVEL, CHECKING .

-- Install the left and right front wheel housing liner, refer to Wheel Housing Liner .

-- Install the noise insulation .

-- Attach the wheels Wheels, Tires and Vehicle Alignment[For engine(s) CDVB, CPRA, CBTA, CPKA, CKRA, CBUA] Wheels and Tires, Matching .