Removal And Installation: Transmission: Installing

WARNING: This page is about a different car, the 2011 Volkswagen CC, 2010 Volkswagen CC, and 2009 Volkswagen CC. However, it is still accessible from the selected car via links, so may be relevant.

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 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

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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 .

-- Tighten the bracket T10346 with the bolt -1- in the left threaded hole in the subframe.

-- Install the bracket T10346 in the same angled position as the engine.

-1- = M6 x 20 bolt

-- Secure the engine support device 3300 A to the bracket T10346.

Fig 2: Identifying Bracket T10346 Installed With Bolt In Left Threaded Hole In Subframe

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-- Push the engine forward using the spindle on the engine support device 3300 A. Note the following when doing this:

Fig 3: Identifying Air Conditioning (A/C) Compressor & Refrigerant Line

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The Air Conditioning (A/C) compressor must not touch the refrigerant line -1- -arrow-.
The generator must not touch the refrigerant line.
The pressure pipe must not touch the radiator.

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

Fig 4: Identifying Support Elements Installed 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.

-- 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 5: Inserting Engine/Transmission Connecting Bolt

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-- Secure the transmission on 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 vehicle direction.

NOTE:

Pay attention to the lines when installing the transmission.

-- Using the spindles on the transmission support 3282, adjust the transmission so that the differential area is rotated in the -direction of arrow-.

Fig 6: Using Spindles Of Transmission Support 3282 To Adjust Transmission

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-- Move the transmission using the spindles on the transmission support 3282 into an angled position.

Fig 7: Moving Transmission Using Spindles On Transmission Support 3282 Into An Angled Position

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-- Guide the transmission and the differential over the subframe -A- in the -direction of the arrow-.

Fig 8: Identifying Longitudinal Member

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-- When doing this, be careful of the longitudinal member -arrows-

Fig 9: Guiding Right Flange Shaft Past Flywheel And Opening In Intermediate Plate

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-- Move the transmission toward the rear to the subframe.

After that, the right flange shaft -1- must be guided past the flywheel and the cut-out -arrow- in the intermediate plate.

-- 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 10: 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 .

-- Remove the engine support device 3300 A and bracket T10346.

Fig 11: Identifying 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.

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

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

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

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

Fig 12: Identifying Transmission Mount Bracket To Transmission Bolts

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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 13: Aligning Engine/Transmission In Installed Location

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

NOTE:

Install the engine/transmission mount free of tension. Refer to Description and Operation .

WARNING:

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

-- Install the flywheel cover plate -A-, if equipped -arrows-. Refer to TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS

Fig 14: Identifying Cover Plate & Right-Hand Drive Flange

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NOTE:

There are threaded inserts (for example a "HeliCoil") in the pendulum support bolt holes in the transmission.

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

Fig 15: 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. Refer to Specifications .

Fig 16: Identifying Transmission Pendulum Support

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-- Install the exhaust system. Refer to Removal and Installation .

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

Fig 17: Identifying Drive Axle Heat Shield Bolts And Shield

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

-- Install the left coupling rod. Refer to Specifications .

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

Fig 18: Identifying Left Front Level Control System Sensor

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-- Install the fan shroud -arrow- and fans. Refer to Removal and Installation .

Fig 19: Identifying Fan Shroud

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-- Install the charge air hose -arrow 2-. Refer to Description and Operation .

Fig 20: Disconnecting Connection On Air Duct Pipe Between Charge Air Cooler And Charge Air Pressure Sensor G31 Intake Manifold

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-- 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 on 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 21: Identifying Ground Strap & Back-Up Light Switch F4 Electrical Harness Connector

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-- 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 22: Identifying Hose/Line Assembly/Pipe & Breather Assembly/Slave Cylinder Clip

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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 item 10.

Fig 23: Identifying Transmission Cable Bracket Bolts

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-- Insert the selector cable into the cable retainer.

Fig 24: Identifying Lock Washer -1- And Pin -Arrow- On Transmission Shift Lever -2-

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

-- Replace the lock washer -1- after every disassembly.

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

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

-- Install the air filter housing, if it was removed earlier. Refer to Removal and Installation .

-- 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 .

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

-- 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 25: Identifying Transmission Tightening Specifications

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TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS

Item	Bolt	Quantity	Nm
1	M12 x 55 With a long M8 threaded pin	1	80
2	M12 x 55 With a short M8 threaded pin or M12 x 50 Without threaded pin	1	80
3	M12 x 165 With an M8 threaded pin Also starter to transmission	2	80
4	M10 x 105	1	40
5	M10 x 50	2	40
6	M12 x 70 or M12 x 65	1	80
-	M6 x 8 Small flywheel cover plate (not present on all engines)	1	10

-A- : Centering alignment sleeves

Transmission Mount Bracket to Transmission

Fig 26: Identifying Transmission Mount Bracket To Transmission Bolts

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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 27: 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 Description and Operation .