Transmission, Installing
Refer to "Transmission, Removing" to get a list of the special tools needed. Refer to TRANSMISSION, REMOVING .
Always replace self-locking nuts and bolts.
Replace bolts that were tightened with an additional turn after removing them.
Install any cable ties that were loosened or cut off during removal at their same location.
Clean the input shaft splines and (on used clutch plates) the hub splines. Remove any corrosion and then apply a very thin coat of Grease for Clutch Disc Shaft Splines :G 000 100 on the splines. Then move the clutch plate 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.
-- The alignment sleeves for centering the engine/transmission must be present inside the cylinder block. Install them if they are missing.
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).
Engage the intermediate plate on the sealing flange and push it onto the alignment sleeves -arrows-.
-- Check the 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 33 :3282/33 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 illustrated on the Adjustment Plate.
-- Install the Mounting Element -C- instead of the Transmission Support - Pins 29 :3282/29 .
-- 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 - Pins 29 :3282/29 into the rear hole for the pendulum support bolt on the transmission.
-- Secure the Slide Hammer Set - Adapter 40 :VW771/40 inside the threaded hole in the transmission housing as illustrated.
-- Secure the transmission on the Transmission Support :3282 using the bolt (M10 X 20) -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.
Pay attention to the lines when installing the transmission.
-- Lift the transmission carefully.
-- Carefully push the engine forward slightly with a second technician.
-- Using the spindles on the Transmission Support :3282 , turn the transmission upward near the differential and turn it downward near 6th gear.
-- Guide the transmission and differential -A- over the subframe.
- The right flange shaft must be guided past the flywheel -arrow 2- ; pay attention to the intermediate plate -arrow 1-.
-- 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.
- Brake fluid can escape from the bleeder on the transmission.
-- Insert engine/transmission bolt -C- and tighten to tightening specification. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .
-- Install lower engine/transmission connecting bolts and tighten to tightening specification. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .
-- Install the engine/transmission connecting bolt -arrow- and tighten it to the tightening specification. Refer to TRANSMISSION 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 TIGHTENING SPECIFICATIONS .
-- Attach the gearshift lever to the transmission gearshift shaft. Refer to 19 and tighten the nut. Refer to OVERVIEW - OPERATING CABLES .
-- Install the relay lever together with the cable retainer. Refer to Removing .
-- Attach the bracket -1- with the new hex 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 bracket -1- is in complete contact with the left subframe mount -2-.
Risk of damaging threads in transmission bracket by inserting bolts crooked.
- Before installing bolts -arrows-, 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 [For engine(s) CZTA] Subframe Mount[For engine(s) CBPA] Subframe Mount[For engine(s) CNLA] Subframe Mount[For engine(s) CPPA, CPRA, CPKA, CPLA] Subframe Mount .
-- Install the new hex bolts -arrows- of the left subframe mount -2- in the bracket -1- and tighten to the tightening position. Refer to OVERVIEW - SUBFRAME MOUNT .
Only remove the Engine Support Bridge :10-222A when all subframe mount bolts are tightened to the tightening specification.
-- Install the flywheel cover plate -A- (if equipped) -arrows-. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .
There are threaded inserts (for example "Heli Coil") in the pendulum support fastening holes.
How to recognize: there is a collar on the first thread -arrow-.
Make sure to use the appropriate bolts and observe the tightening specification. Refer to [For engine(s) CZTA] Subframe Mount[For engine(s) CBPA] Subframe Mount[For engine(s) CNLA] Subframe Mount[For engine(s) CPPA, CPRA, CPKA, CPLA] Subframe Mount .
-- Install the pendulum support. Refer to [For engine(s) CZTA] Subframe Mount[For engine(s) CBPA] Subframe Mount[For engine(s) CNLA] Subframe Mount[For engine(s) CPPA, CPRA, CPKA, CPLA] Subframe Mount .
-- Install the drive axles. Refer to Drive Axle .
-- Attach the drive axle heat shield -arrows- (if equipped). Refer to Drive Axle .
-- Install the left coupling rod. Refer to Subframe .
-- Connect the connector -1- to the Oil Level Thermal Sensor -G266-.
-- Assemble the exhaust system and attach the exhaust system bracket to subframe. Refer to [For engine(s) CPPA, CPRA, CPKA, CPLA] Exhaust System, Emission Controls[For engine(s) CBPA] Exhaust System, Emission Controls[For engine(s) CVCA] Exhaust System, Emission Controls[For engine(s) CNLA] Exhaust System, Emission Controls .
-- Install the air shroud -arrow- together with the coolant fans. Refer to [For engine(s) CZTA] Radiator/Radiator Fan[For engine(s) CBPA] Radiator/Coolant Fan[For engine(s) CNLA] Radiator/Radiator Fan[For engine(s) CVCA] Radiator/Radiator Fan[For engine(s) CPPA, CPRA, CPKA, CPLA] Radiator/Radiator Fan .
-- Attach the charge air pipe to the engine. Refer to [For engine(s) CNLA] Charge Air Pressure ActuatorV465, Removing and Installing[For engine(s) CVCA] Charge Air System[For engine(s) CPPA, CPRA, CPKA, CPLA] Charge Air System[For engine(s) CZTA] Charge Air System .
-- Install the left charge air hose -arrow 1- and -arrow 2-. Refer to [For engine(s) CNLA] Charge Air Pressure ActuatorV465, Removing and Installing[For engine(s) CVCA] Charge Air System[For engine(s) CPPA, CPRA, CPKA, CPLA] Charge Air System[For engine(s) CZTA] Charge Air System .
-- Attach the right charge air hose to the charge air cooler. Refer to [For engine(s) CNLA] Charge Air Pressure ActuatorV465, Removing and Installing[For engine(s) CVCA] Charge Air System[For engine(s) CPPA, CPRA, CPKA, CPLA] Charge Air System[For engine(s) CZTA] Charge Air System .
-- Position the starter and install the lower bolt. Refer to 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 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 25mm :3094 from the hose/line assembly or from the return hose.
-- Bend the supply hose back into its original shape after removing the Hose Clamps - Up To 25mm :3094 .
-- Bleed the clutch system. 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 Hydraulic Components .
-- Attach the cable mounting bracket to the transmission and tighten the bolts and nuts -arrows- to the tightening specification. Refer to OVERVIEW - OPERATING CABLES .
-- Install the selector cable in the cable retainer.
-- Apply a small amount of grease on the pins -arrow- for the gearshift lever -2-.
Grease allocation. Refer to the Parts information.
-- Replace the lock washer -1- each time it is removed.
-- Adjust the gearshift mechanism. Refer to SELECTOR MECHANISM, ADJUSTING .
-- Install the plenum chamber cover. Refer to Bulkhead .
-- Install the bolts -arrows- for the left and right lock carrier brackets to the tightening specification. Refer to Lock Carrier .
-- Install the battery tray and the battery. Refer to Battery, Starter, Generator, Cruise ControlBattery, Starter, Generator, Cruise Control .
-- Install the air filter. Refer to [For engine(s) CVCA] Air Filter or [For engine(s) CNLA] Air Filter[For engine(s) CZTA] Air Filter[For engine(s) CBPA] Air Filter[For engine(s) CPPA, CPRA, CPKA, CPLA] Air Filter .
-- Install the engine cover. Refer to [For engine(s) CZTA] Engine Assembly[For engine(s) CBPA] Engine Assembly[For engine(s) CNLA] Engine Assembly[For engine(s) CVCA] Engine Assembly[For engine(s) CPPA, CPRA, CPKA, CPLA] Engine Assembly .
-- Connect the battery and follow the procedure regarding what to do after connecting a battery. Refer to Battery, Starter, Generator, Cruise ControlBattery, Starter, Generator, Cruise Control .
-- Check the transmission fluid level. Refer to TRANSMISSION FLUID LEVEL, CHECKING .
-- Install the left front wheel housing liner. Refer to Wheel Housing Liner .
-- Install the noise insulation. Refer to Noise Insulation .
-- Install the wheel. Refer to Wheels, Tires, Wheel AlignmentWheels, Tires, Wheel AlignmentWheels, Tires, Wheel Alignment .