Transmission, Installing

NOTE:

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

Pay attention to the following chart for the subject - :

"Transmission Fluid, Checking and Filling"
		>>No<<	>>Yes<<	>>Yes<<
Transmission	Original Part	X
	No fluid leaking	X
	Was completely disassembled		X before installation -item ) OVERVIEW - TRANSMISSION HOUSING - List Item: Fluid Filler Plug transmission fluid capacity. Refer to CAPACITIES
	Was partially disassembled (The transmission housing and the clutch housing were not separated from each other)			X after installation. Refer to TRANSMISSION FLUID .

-- Use a thread cutter to carefully clean all threaded holes containing self-locking bolts to remove any locking fluid residue.

-- Replace self-locking bolts and nuts after removing them.

-- 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 fits correctly on the engine.

-- Clean the splines on the input shaft and then lubricate them lightly with Grease for Clutch Plate Shaft Splines.

It must be possible to slide the clutch plate back and forth on the input shaft.

The : 3282 is set up with the : 3282/39 to install the transmission.

Fig 1: Identifying Transmission Support Adjustment Plate

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Align the arms of the : 3282 so that they align with the holes in the Adjustment Plate.

-- Install the Mounting Elements -A and C- (Transmission Support - Pins 29: 3282/29 ) as shown on the Adjusting Plate.

-- Place the transmission on the Engine and Gearbox Jack.

-- Align the Adjusting Plate and transmission so that they are parallel to each other.

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

Fig 2: Aligning Adjustment Plate Parallel To Transmission And Lock Safety Supports On Transmission

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Position the Engine and Gearbox Jack under the vehicle. The -arrow symbol B- on the adjusting plate points in direction of travel.

-- On a new transmission or replacement transmission remove the right flange shaft -arrow-.

Fig 3: Locating Right Flange Shaft Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Check the flange shaft seal for leaks and replace if necessary. Refer to SEALS .

-- Install the spindle -A- from the : 3066 in the threaded piece on the differential.

Fig 4: Identifying Thrust Piece And Nut

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the : T10148 and secure with the nut -B-.

NOTE:

The : T10148 protects the right seal and the transmission from dirt.

An M8 x 105 mm bolt may be installed by hand into the differential threaded piece instead of a spindle -A-.

-- Tip the transmission forward in the direction of -arrow- using the spindle on the : 3282 .

Fig 5: Identifying Engine/Transmission Jack

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Push the engine forward slightly with a second technician.

-- Carefully lift the transmission with the : VAS6931 , while making sure that the seal -1- is guided through without any damage to the pressure plate -arrow-.

Fig 6: Identifying Left Flange Shaft

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-- Guide the left flange shaft -B- past the subframe -arrow-.

Fig 7: Identifying Right Flange Shaft And Hole

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Align the transmission with the engine and install it.

-- Tighten the engine/transmission connecting bolt -A- above the right flange shaft with the tightening specification.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Reinsert the right flange shaft and tighten the countersunk bolt -arrow- to the tightening specification.

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

-- After the transmission is attached to the engine, remove the Engine and Gearbox Jack from the transmission.

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

-- Attach the transmission bracket -A- with new hex collar bolts to the transmission -arrows- and tighten. Refer to OVERVIEW - ASSEMBLY MOUNTS .

Fig 8: Identifying Transmission Plate Bolts

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-- Align the engine/transmission in its installation position. To do so, lift it just enough so that the transmission completely touches the left subframe mount.

-- Align the engine/transmission in the installation position via both spindles of the : 10-222A .

Fig 9: Identifying Left Subframe Mount

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

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

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

NOTE:

Install the engine/transmission mount free of tension. Refer to ASSEMBLY MOUNT, ADJUSTING .

-- Install new bolts -arrows- and tighten. Refer to OVERVIEW - ASSEMBLY MOUNTS .

CAUTION:

Risk of accident!

Only remove the : 10-222A if all of the bolts for the assembly mount are tightened to the tightening specification.

-- If equipped, install the ground wire on the transmission mount -arrow-.

Fig 10: Identifying Nut

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the pendulum support with new bolts -1 to 3-. Refer to PENDULUM SUPPORT, REMOVING AND INSTALLING .

Fig 11: Identifying Bolts

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-- Assemble the exhaust system and attach the exhaust system bracket to the subframe. Refer to OVERVIEW - MUFFLER .

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

Fig 12: Drive Axle Heat Shield

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- If equipped, install the right drive axle heat shield on the engine -arrows-. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

-- If equipped, install the Left Front Level Control System Sensor -G78- on the lower control arm. Refer to LEFT FRONT LEVEL CONTROL SYSTEM SENSOR -G78- /RIGHT FRONT LEVEL CONTROL SENSOR -G289-, REMOVING AND INSTALLING .

Fig 13: Identifying Left Front Level Control System Sensor

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the coupling rod -3- on the stabilizer bar -2- on both sides. Refer to OVERVIEW - SUBFRAME .

Fig 14: Coupling Rod And Nuts And Stabilizer Bar

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 15: Disconnecting Connector From Oil Level Thermal Sensor G266

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Transmission for vehicles with Start/Stop System: connect the connector -arrow- to the Transmission Neutral Position Sensor -G701-.

Fig 16: Connect The Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the connector -1- to the Back-Up Lamp Switch -F4-.

Fig 17: Identifying Back-Up Light Switch And Starter Connectors

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-- Install the starter by connecting the connector -arrow 2- and installing the line -arrow 3-. Refer to STARTER, REMOVING AND INSTALLING .

-- Install the bracket for the wires -arrow-.

Fig 18: Identifying Removal Of Nut And Wiring Bracket From Threaded Stud

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the clutch slave cylinder and tighten the bolts -B arrows-. Refer to OVERVIEW - CLUTCH RELEASE MECHANISM .

Fig 19: Identifying Transmission Support And Slave Cylinder

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install and secure the transmission support -A arrows-. Refer to OVERVIEW - ASSEMBLY MOUNTS .

-- Make sure the vacuum hose for the brake system is installed correctly. If necessary, install the vacuum hose. Refer to OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER .

-- Attach the bracket -B- to the transmission.

Fig 20: Identifying Cable Bracket Support Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Press the hose/line assembly -A- into the bracket -B- on the transmission.

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

-- Install the gearshift lever -A-. Refer to Figure.

Fig 21: Identifying Transmission Shift Lever -A- And Nut -Arrow 3-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the nut -arrow 3-. Refer to OVERVIEW - SHIFT UNIT .

-- Insert the relay lever together with the cable retainer and secure with the clip -arrow 1-. Refer to Figure. While doing so, grease the relay lever and the gearshift lever guide rail.

Determine the shift mechanism grease using the Parts Information.
The clip -arrow 1- secures the relay lever.
Make sure the clips locks securely.

-- Coat the pin on the gearshift lever with a small amount of grease -A-.

-- Place the shift cable on the selector lever -A- and secure with the new lock washer -arrow 2-.

-- Connect the selector cable to the cable retainer.

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

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

NOTE:

If when removing the flange shaft, the transmission fluid leaks out, drain and fill the transmission fluid for the installed transmission and flange shaft. Refer to TRANSMISSION FLUID .

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

-- Install the cover for the engine and/or air filter. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Install the filler tube for the windshield washer system washer fluid reservoir. Refer to WASHER FLUID RESERVOIR, 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 .

-- Install the wheel. Refer to WHEEL BOLTS TIGHTENING SPECIFICATION .

-- Check the headlamp adjustment on vehicles with Left Front Level Control System Sensor -G78-. Refer to HEADLAMP, ADJUSTING .