Transmission, Installing

Installing

-- Install the manual transmission together with the bevel box.

NOTE:

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

Replace self-locking screws and nuts after removing them.

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 selector 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-.

Fig 1: Identifying Intermediate Plate Alignment Bushings

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-- 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 : 3282 with the : 3282/33 in order to install the transmission.

Fig 2: Identifying Adjustment Plate Installed Onto Transmission Support

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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 Mounting Element -C- instead of the : 3282/29 .

-- Place the transmission on the : VAS6931 .

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

-- Install the : 3282/29 into the rear hole for the pendulum support bolt on the transmission.

Fig 3: Identifying Engine/Transmission Connecting Bolt

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-- Secure the : VW771/40 inside the threaded hole in the transmission housing as illustrated.

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

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

-- Position the : VAS6931 under the vehicle. The arrow on the adjusting plate points in direction of travel.

NOTE:

Pay attention to the lines when installing the transmission.

-- Using the spindles on the : 3282 , position the transmission slightly upward in the area of the differential/bevel box.

-- Lift the transmission carefully.

-- Guide the bevel box and flange -C- past the driveshaft -A- and exhaust system -B-.

Fig 4: Pulling On Drive Axle And Front Exhaust Pipe With Output Flange

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

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

CAUTION:

Brake fluid can escape from the bleeder on the transmission.

-- Install the engine/transmission connecting bolt -C- (→ illustration above) and tighten. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

-- Install the engine/transmission connecting bolts -1 and 2- tighten them. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

Fig 5: Identifying Lower Connecting Bolts For Engine/Transmission

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-- Install all engine/transmission connecting bolts and tighten them. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

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

-- Install all upper engine/transmission connecting bolts and tighten. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

-- Attach the gearshift lever to the transmission gearshift shaft. Refer to Figure and tighten the nut. Refer to OVERVIEW - SELECTOR MECHANISM .

-- Install the selector relay lever together with the cable retainer. Refer to Figure.

CAUTION:

Risk of damaging the threads in the transmission support by inserting bolts crooked.

The transmission mount and bracket must be parallel to each other in order to prevent the transmission support thread does not become damaged.

-- Install transmission bracket -1- with new bolts -arrows-. Refer to OVERVIEW - SUBFRAME MOUNT .

Fig 6: Identifying Transmission Bracket (1) Bolts

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-- Tighten the : 10-222A spindles until the transmission support -1- touches the transmission mount -2- to align the engine/transmission sub-assembly in installed position.

Fig 7: Aligning Engine/Transmission In Installed Location

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-- Install new bolts -arrows- and tighten. Refer to OVERVIEW - SUBFRAME MOUNT .

NOTE:

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

-- If present, connect ground cable -arrow-.

Fig 8: Identifying Nut

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CAUTION:

Risk of accident!

Only remove : 10-222A when all subframe mount bolts are tightened to the tightening specification.

-- Connect hose/line assembly with bleeder. Refer to Fig 9.

Fig 9: Disconnect and Connect Clutch Mechanism Wires

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Fig 10: Identifying Hose Clamps 3094, Clamp Supply Hose And Master Cylinder

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-- After removing the : 3094 , the supply hose must be formed back into its original shape.

-- 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 OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER .

-- Mount the cable bracket on the transmission and tighten the bolts and nuts -arrows-. Refer to OVERVIEW - SELECTOR MECHANISM .

Fig 11: Identifying Transmission Cable Bracket Bolts

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-- Install the selector cable in the cable retainer.

Fig 12: Identifying Lock Washer -1- And Pin -Arrow- On Transmission Shift Lever -2-

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

-- Connect the front left connectors to the transmission:

Fig 13: Identifying Park/Neutral Position Switch

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Transmission for vehicles with start/stop system: Transmission Neutral Position Sensor -G701-
Back-Up Lamp Switch -F4-

-- Attach the transmission support while paying attention to the tightening sequence of bolts -1 and 2-. Refer to Figure.

Fig 14: Bevel Box Transmission Support Tightening Sequence

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-- Attach the driveshaft with the flexible disc to the bevel box flange -arrows-. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

Fig 15: Driveshaft Flexible Disc

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-- Attach heat shield -1- -arrows-. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

Fig 16: Identifying Heat Shield

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-- Assemble the exhaust system. Refer to OVERVIEW - MUFFLER .

-- Install the subframe together with pendulum support. Refer to OVERVIEW - SUBFRAME .

Fig 17: Identifying Pendulum Support

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NOTE:

Threaded inserts (for example, "Heli Coil") are found in the pendulum support fastening holes on some transmissions. Refer to Figure.

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

NOTE:

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

-- Check gear oil in the bevel box. Refer to GEAR OIL IN BEVEL BOX, FILLING .

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

Fig 18: Identifying Right Drive Axle Heat Shield

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

-- Connect the connector -1- to the Oil Level Thermal Sensor -G266-.

Fig 19: Disconnecting Connector From Oil Level Thermal Sensor G266

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

-- If unclipped, carefully clip in the A/C system pipe and do not disconnect the line system. Refer to SYSTEM OVERVIEW - REFRIGERANT CIRCUIT .

-- Install fuel filter. Do not open the line system. Refer to OVERVIEW - FUEL DELIVERY UNIT/FUEL LEVEL SENSOR .

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

-- Install the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

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

-- Install the windshield wiper arms. Refer to WINDSHIELD WIPER ARMS, REMOVING AND INSTALLING .

-- Install the lower section of the left front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

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