Transmission, Installing: Procedure

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

-- Always replace self locking nuts and bolts.

-- 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 splines on the input shaft and then lubricate them lightly with grease for clutch plate splines G 000 100.

It must be possible to slide the clutch disc 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 .

To install the transmission the Transmission Support - Mounting Plate 333282/33 must be installed on the Transmission Support 3282.

-- 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 Transmission Support - Pins 293282/29 in place on the adjustment plate -C-.

-- Place the transmission on the Engine/Gearbox Jack V.A.G 1383 A.

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

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

-- Secure the Slide Hammer Set - Adapter 40 VW 771/40 inside the threaded hole in the transmission housing as shown.

-- Secure the transmission to the Transmission Support 3282 with a M10 x 20 bolt -A-.

The arm -B- must be flush with the guide on the Transmission Support 3282 -arrow-.

-- Place the Engine/Gearbox Jack V.A.G 1383 A under the vehicle. The arrow points in the drive direction.

-- 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: Guiding Right Flange Shaft Past Flywheel

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- The right flange shaft -1- must be guided over the bolt flange -2- on the cylinder block.

-- Change the position of the transmission using the spindles on the transmission support 3282 so that it does not come in 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 join it.

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

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

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

-- Remove the Transmission Support 3282 after the transmission is bolted to the engine at the bottom.

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

-- Install the transmission shift lever to the transmission gear shift shaft, refer to Figure and tighten the nut to specification. See -item 6- in SHIFT AND SELECTOR CABLES .

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

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

-- Install the transmission mount bracket -1- to the transmission with new bolts -arrows- and tighten them to specification. Refer to ENGINE AND TRANSMISSION MOUNTS AND BRACKETS OVERVIEW .

-- 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-.

-- Install new transmission mount -2- to transmission mount bracket bolts -arrows- and tighten them to specification. Refer to ENGINE AND TRANSMISSION MOUNTS AND BRACKETS OVERVIEW .

-- Install the flywheel cover plate in the -direction of the arrow- and install the bolt -arrow-, if equipped. Refer to TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS .

-- Install the drive axles to the transmission. Refer to REMOVAL AND INSTALLATION .

-- Install the right drive axle heat shield and bolts -arrows-, if equipped. Refer to REMOVAL AND INSTALLATION .

-- Install the subframe with steering gear. Refer to REMOVAL AND INSTALLATION .

-- Secure the pendulum support to the transmission using new bolts. Refer to Special Tools .

-- Connect the connector -1- to the oil level thermal sensor -G266-.

-- Assemble the exhaust system and attach the exhaust system suspended mount to the subframe. Refer to one of the following:

Gas engine, refer to Removal And Installation ,REMOVAL AND INSTALLATION .

Diesel engine, refer to DESCRIPTION AND OPERATIONREMOVAL AND INSTALLATION .

-- Install the starter and tighten the lower bolts.

-- 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 REMOVAL AND INSTALLATION .

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

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

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

-- Pull on the hose/line assembly or pipe to make sure it is secure.

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

-- Bend the supply hose back into its original shape after removing the hose clamp up to 25 mm diameter 3094.

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

-- Make sure the vacuum hose for the brake system is installed correctly. Refer to REMOVAL AND INSTALLATION .

-- Attach the cable bracket to the transmission and tighten the bolts and nut -arrows- to specification. See -items 13 and 16- in SHIFT AND SELECTOR CABLES .

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

• Use the correct grease allocation.

-- Secure the shift cable -2- to the transmission shift lever pin -arrow- with a new lock washer -3-.

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

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

-- Install the plenum chamber cover. Refer to Removal And Installation .

-- Install the lock carrier trim and the bolts -arrows- for the left and right front end brackets. Refer to Removal And Installation .

-- Install the battery tray and the battery. Refer to REMOVAL AND INSTALLATION .

Vehicles With a Diesel Engine 

-- Attach the charge air hose to the turbocharger and secure it with the bolt -2-.

-- Attach the crankcase ventilation hose -1- and clip the vacuum hoses to the charge air hose -arrows-.

-- Connect the crankcase ventilation hose connection -1-.

Continuation for All Vehicles 

-- Install the complete air filter housing, refer to one of the following:

Gas engine, refer to Removal And Installation ,REMOVAL AND INSTALLATION .

Diesel engine, refer to DESCRIPTION AND OPERATIONREMOVAL AND INSTALLATION .

-- Install the engine cover. Refer to Removal And Installation ,REMOVAL AND INSTALLATION .

-- Connect the battery and follow the procedure regarding what to do after connecting the battery. Refer to REMOVAL AND INSTALLATION .

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

-- Install the left front wheel housing liner. Refer to REMOVAL AND INSTALLATION .

-- Install the noise insulation. Refer to Removal And Installation .

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