Transmission, Installing

NOTE:

Refer to "Transmission, Removing" TRANSMISSION, REMOVING for a list of the special tools needed.

Install in reverse order of removal while noting the following:

NOTE:

Always replace the needle bearing -arrow- after separating the engine and transmission.

Fig 1: Checking Needle Bearing Inside Crankshaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

If the needle bearing in the crankshaft is damaged, the gears will no longer shift correctly.

-- Replace the needle bearing in the crankshaft. Refer to CRANKSHAFT NEEDLE BEARING, REPLACING .

-- Transmission pins (not splines) must also be lightly lubricated.

-- Make sure both alignment sleeves between the engine and the transmission fit correctly.

-- Make sure the intermediate plate fits correctly.

Pay Attention to the Selector Lever Cable When Lifting the transmission. Guide the Selector Lever Cable into the Cable Bracket as Early as Possible.

The cable is not lubricated.

Guide the Engine and Transmission Together by Hand Until the Entire Surface of Both Flanges Come into Contact with one Another.

-- Adjust the transmission support until the engine and transmission are aligned.

-- Turn the crankshaft slightly if necessary.

-- Insert transmission without pinching any lines.

-- Attach the transmission to the engine. Tightening Specifications, Transmission to Engine. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

Install the left subframe mount as follows:

Fig 2: Identifying Transmission Support Plate And Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Replace all bolts -1 and 2- for the left subframe mount.

-- Install all new bolts first by hand.

-- Fasten the transmission bracket -A- to the transmission using the bolts -1-.

-- Align the engine/transmission in its installed position. Lift until the transmission bracket is touching the transmission mount completely.

CAUTION:

There is a risk of damaging threads in transmission bracket by inserting bolts at an angle.

Before installing the bolts -2-, the transmission bracket and transmission mount support arm must be absolutely parallel to each other. If necessary, lift the back of the transmission using the Engine and Gearbox Jack.

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

-- Tighten the bolts -2- to the tightening specification.

WARNING:

Only remove the Engine Support Bridge: 10-222A when all the left and right subframe mount bolts are tightened to the tightening specification.

-- Remove the Engine Support Bridge: 10-222A .

-- Install the starter. Refer to STARTER, REMOVING AND INSTALLING .

Connect the connector -A- from the DSG Transmission Mechatronic -J743- as follows.

Fig 3: View Of Installing Connector -A- On DSG Transmission Mechatronic -J743

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- The arrow -D- on the Mechatronic -B- must line up with the connector -A- as well as with the tab -C-.

-- Connect the connector -A- carefully all the way and then turn the lock >>clockwise<< in direction of -arrow-.

-- Attach the drive axles to the transmission. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Install the heat shield over the right drive axle. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

-- Install the subframe with the steering gear. Refer to SUBFRAME WITH STEERING GEAR, REMOVING AND INSTALLING .

-- Install the pendulum support with new bolts on the transmission. Refer to OVERVIEW - SUBFRAME MOUNT .

Fig 4: Identifying Pendulum Support

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Selector lever cable lock washers -arrows- must be replaced.

Fig 5: Identifying Lock Washers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Always adjust selector lever cable. Refer to SELECTOR LEVER CABLE, CHECKING AND ADJUSTING .

-- Attach the coolant hoses to the transmission fluid cooler.

-- Check the coolant level and fill if necessary. Refer to COOLANT, DRAINING AND FILLING .

-- Assemble the exhaust system and attach the exhaust system bracket to the subframe. Refer to OVERVIEW - EMISSIONS CONTROL (CPLA, CPPA, CPKA, CPRA) .

-- Install the plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Install the lock carrier trim and the bolts -arrows- for the left and right lock carrier brackets. Refer to OVERVIEW - LOCK CARRIER .

Fig 6: Identifying Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the battery tray and the battery. Refer to BATTERY TRAY, REMOVING AND INSTALLING and BATTERY, REMOVING AND INSTALLING .

-- Install the complete air filter housing:

Gasoline engine. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .
Diesel engine. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Connect the battery and follow the steps after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING (CPLA, CPPA, CPKA, CPRA) .

-- Check the transmission fluid level and if necessary fill. Refer to TRANSMISSION FLUID LEVEL, CHECKING .

-- Install the left and right front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Install the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- Attach the front wheels. Refer to WHEEL BOLT TIGHTENING SPECIFICATIONS .