Transmission
Transmission
=> [ Removing ]
=> [ Installing ]
Special tools, testers and auxiliary items required
• Engine Support Bridge (10-222 A)
• Engine Support Feet (10-222 A/8)
• Engine Support Adapter (10-222 A/3)
• Adapter (10-222 A/18)
• Transmission Support (3282)
• Support Elements (Pins) (2382/29)
• Adjustment Plate (3282/33)
• Transmission Support Jig (3336)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Engine/Transmission Jack (V.A.G 1383 A)
• Bracket (T10346)
• Engine Support Device (3300 A)
• Adapter (VW 771/40)
• Hose Clamps up to 25 mm Dia. (3094)
• Grease for Clutch Plate Splines (G 000 100)
• Grease (G 000 450 02)
• M6 x 20 Bolt
• M6 x 80 Bolt
• M10 x 20 Bolt
Removing
The engine support bridge (10-222 A) and the engine support feet (10-222 A/8) will be mounted on the longitudinal members later in the procedure.
• To protect the edges of the fenders, cover both engine support feet (10-222 A/8) with cloth tape - arrow -. Refer to the Parts Catalog.
Removing
- See if a coded radio is installed. If so, obtain the antitheft code.
- Turn off the ignition and disconnect the battery ground cable.
Later in the procedure, the engine support bridge (10-222 A) is connected to the engine lift eyes.
- Remove the engine cover if it is blocking the lift eyes.
- Remove the air filter housing if it is located near the battery.
- Remove the battery cover, the battery and the battery tray.
- Remove the shift cable lock washer - 1 - from the transmission shift lever - 2 - and remove the cable from the pin - arrow -.
- Remove the cable retainer from the selector cable.
• To avoid damage to the selector cable, the cable retainer must be disconnected from the selector lever before removal.
- Pull the locking mechanism all the way forward in the - direction of arrow 1 - and then unlock it to the left in the - direction of arrow 2 -.
- Press the relay lever forward (in the - direction of arrow 3 -).
- The relay lever is removed together with the cable retainer later in the procedure.
- Remove the cable bracket bolts/nut - arrows - from the transmission, move it to the side and tie it up.
- Clamp the supply hose to the master cylinder using the hose clamps up to 25 mm dia. (3094).
- Remove the circlip for the hose/line assembly or plastic line - A -.
- Remove the hose/line assembly or plastic line from the breather/slave cylinder - arrow - and seal it off.
Do not press the clutch pedal anymore.
- Remove the nut and ground strap - 1 - from the top starter bolt.
- Disconnect the connector - 2 - from the backup lamp switch (F4).
- Disconnect the connector and the wire from the starter.
- Remove the upper engine/transmission bolts - arrows -.
- Remove the upper bolt for the starter.
- Install the bracket (T10346) in the rear most hole out of the three holes for the battery tray.
- Use a M6 x 80 bolt or one of the battery tray bolts for this.
- Disconnect any hoses and wires in the area of the lifting eyes on the engine.
- Install the engine support bridge (10-222 A) in front of the hood support.
- Use the following special tools:
• Engine support adapter (10-222 A/3)
• Engine support feet (10-222 A/8)
• Adapter (10-222 A/18)
- Position the engine support feet (10-222 A/8) :
• On the upper longitudinal members, directly in front of the ridge (- arrow 1 -) next to the bolt (- arrow 2 -)
- Then, attach the engine support bridge to the bracket (T10346).
- Hook the spindles into the left lifting eye on the engine.
- Tension the engine/transmission assembly and the engine support bridge via the spindles.
The left drive axle bolt - arrow - must be removed later in the procedure.
- With the vehicle still resting on its wheels, loosen the left front drive axle bolt - arrow - a maximum of 90°, otherwise the wheel bearing will be damaged.
- Remove the noise insulation.
- Remove the lower part of the left front wheel housing liner.
- Remove the left front level control system sensor (G78) from the control arm, if equipped.
- Remove the bracket from the starter.
- Remove the starter.
- Loosen the left charge air hose clamps - arrows 1 and 2 - and remove the hose.
- Remove the left charge air pipe from the engine.
- Remove the right charge air hose from the charge air cooler.
- Remove the fan shroud - arrow - and fans.
- Remove the exhaust system suspended mount bolts - arrows - from the subframe.
- Separate the exhaust system at the double clamp - arrows -.
- Tie up the front exhaust pipe or lay it on the tunnel bridge.
- Remove the pendulum support bolts and support.
- Disconnect the connector - 1 - from the oil level thermal sensor (G266).
- Remove the coupling rod from the stabilizer bar and move it to the side.
- Remove the left drive axle.
- Remove the drive axle heat shield bolts - arrows - and shield, if equipped.
- Remove the right drive axle from the transmission and tie it up.
- Remove the engine mount - 2 - to engine mount bracket bolts - arrows -.
- Lower the transmission by adjusting the spindles, which are attached to the engine, to approximately 40 mm - a -.
• When moving the engine/transmission assembly, pay attention to the connected lines, hoses and radiator.
- Remove the engine mount bracket - 1 - bolts - arrows - from the transmission.
- Remove the relay lever with the cable retainer. Refer to => [ Plastic Relay Lever ] Description and Operation.
- Remove the transmission shift lever from the gear shift shaft.
- Remove the small flywheel cover plate - A - - arrows -, if equipped.
- Remove the lower engine/transmission bolt - 1 -.
• Loosen the engine/transmission bolt - 3 - and leave it in so that it is hand-tight.
- Install the bracket (T10346) with the bolt - 1 - in the left threaded hole in the subframe.
- 1 - = M6 x 20 bolt
- Install the engine support device (3300 A) to the bracket (T10346).
- Place a cloth between engine support device (3300 A) and the oil pan.
- Push the engine forward using the spindle on the engine support device (3300 A). Note the following when doing this:
• 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 remove the transmission, the transmission support (3282) must be equipped with the adjustment plate (3282/33).
- Install the transmission support (3282) to the engine/transmission jack (V.A.G 1383 A).
- 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 - C -.
- Position the engine/transmission jack (V.A.G 1383 A) under the vehicle. The arrow symbol - B - on the adjustment plate points in direction of travel.
- Align the adjustment plate so that it is parallel to the transmission.
- Install the adapter (VW 771/40) in the threaded hole in the transmission housing as illustrated.
- Install the pin (3282/29) into the hole on the transmission for the pendulum support bolt.
- Secure the transmission to the transmission support (3282) with a M10 x 20 bolt - A -.
The arm - B - must be flush with the guide on the transmission support (3282) - arrow -.
Remove the engine/transmission bolt - arrow -.
- Remove the engine/transmission bolt - C - and the lower engine/transmission bolts.
- Separate the transmission from the engine (alignment sleeves).
- Move the transmission in the area of the differential using the transmission support (3282) spindles into an angled position.
• The differential, near the transmission, must face upward.
The right flange shaft - 1 - must be guided over the bolt flange of the engine - 2 -.
- Guide the transmission and the differential over the subframe - A - and swing it out.
- Pay attention to the longitudinal member - arrows -. Then carefully lower the transmission.
• Pay attention to the lines when lowering the transmission.
Installing
• Refer to "Removing" to get a list of the special tools needed. Refer to => [ Removing ].
• Replace the self-locking nuts and bolts.
• Replace bolts that were tightened to a torque angle.
• Install any cable ties that were loosened or cut off during removal at their same location.
• Clean the input shaft splines and (on a used clutch disc) the hub splines. Remove any corrosion and apply a very thin coating 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 any locking compound residue from all threaded holes using a tap.
- 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 -.
- Check the release bearing for wear. If necessary, replace the slave cylinder and the release bearing. Refer to => [ Slave Cylinder with Release Bearing ] Slave Cylinder with Release Bearing.
- Install the bracket (T10346) with the bolt - 1 - in the left threaded hole in the subframe.
- 1 - = M6 x 20 collar bolt
- Install the engine support device (3300 A) to the bracket (T10346).
- Place a cloth between engine support device (3300 A) and the oil pan.
- Push the engine forward using the spindle on the engine support device (3300 A). Note the following when doing this:
• 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).
- 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 - C -.
- 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.
- Install the adapter (VW 771/40) in the threaded hole in the transmission housing as illustrated.
- Secure the transmission on the transmission support (3282) with an M10 x 20 bolt - A -.
The arm - B - must be flush with the guide on the transmission support (3282) - arrow -.
- Place the engine/transmission jack (V.A.G 1383 A) under the vehicle. The arrow points in the direction of travel.
• Pay attention to the lines when installing the transmission.
- Lift the transmission carefully.
- Now, turn the transmission upward near the rear differential and downward near the 6th gear using the transmission support (3282) spindles.
- 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 bolt flange on the engine - 2 -.
- Change the position of the transmission using the transmission support (3282) spindles so that it does not come in contact with the longitudinal member - arrows -.
- 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.
- Install the lower engine/transmission bolts and tighten them to specification.
- Remove the engine support device (3300 A) and the bracket (T10346).
- Install the engine/transmission bolt - arrow - and tighten it to specification.
- Remove the transmission support (3282) after the transmission is bolted to the engine at the bottom.
- Install the upper engine/transmission bolts and tighten them to specification.
- Attach the transmission shift lever to the gear shift shaft. Refer to => [ Installing the Transmission Shift Lever ] Shift Mechanism Overviews and tighten the nut to specification, see => [ (Item 17) Nut ] Shift Mechanism Overviews.
- Install the relay lever with the cable retainer. Refer to => [ Plastic Relay Lever ] Description and Operation.
- Install the engine mount bracket - 1 - to the transmission with new bolts - arrows - and tighten them to specification.
- Align the engine/transmission in its installed position. Lift it until the engine mount bracket - 1 - is in complete contact with the transmission mount - 2 -.
- Install the new engine mount to engine mount bracket bolts - arrows - and tighten them to specification.
• Install the transmission mount free of tension.
Only remove the engine support bridge (10-222 A) when all the transmission mount bolts are tightened to specification.
- Install the flywheel cover plate - A - (if equipped).
• There are threaded inserts (for example a "Heli-Coil") in the pendulum support holes in the transmission.
• How to recognize: there is a collar on the 1st thread - arrow -.
- Install the pendulum support.
- Install the drive axles.
- Install the drive axle heat shield and bolts - arrow -, if equipped.
- Install the left coupling rod.
- Install the left front level control system sensor (G78) to the control arm, if equipped.
- Connect the connector - 1 - to the oil level thermal sensor (G266).
- Assemble the exhaust system and attach the suspended mount to the subframe.
- Install the fan shroud - arrow - and fans.
- Install the charge air pipe to the engine.
- Install the left charge air hose and tighten the clamps- arrows 1 and 2 -.
- Install the right charge air hose to the charge air cooler.
- Install the starter and tighten the lower bolt.
- Attach the bracket for the lines to the lower starter bolt.
- Install the top bolt for the starter and attach the connectors and the cables to the starter.
- Install the ground strap - 1 - and nut to the upper starter bolt.
- Connect the connector - 2 - to the backup lamp switch (F4).
- Push the hose/line assembly or plastic line - A - into the breather/slave cylinder up to the stop and push the circlip - arrow - downward.
- Pull on the line to make sure it is secure.
- Remove the hose clamps up to 25 mm dia. (3094) from the hose.
- After removing the hose clamps up to 25 mm dia. (3094) , bring the hose back to its original shape.
- Bleed the clutch system. Refer to => [ Clutch System, Bleeding ] 02Q Transmission.
- Make sure the vacuum hose for the brake system is installed correctly.
- Install the cable bracket to the transmission and tighten the bolts/nut - arrows - to specification, see => [ (Item 6) Bolt ] Shift Mechanism Overviews and => [ (Item 10) Nut ] Shift Mechanism Overviews.
- Insert the selector cable into the cable retainer.
- Apply a small amount of grease (G 000 450 02) 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 ] Adjustments.
- Install the battery tray, the battery and the cover.
- Install the air filter housing, if it was removed earlier.
- Install the engine cover, if necessary.
- Connect the battery and then complete the steps after connecting the battery.
- Check the transmission fluid level. Refer to => [ Transmission Fluid, Checking ] Service and Repair.
- Install the lower section of the left front wheel housing liner.
- Install the noise insulation.
- Check the headlamp adjustment if the vehicle has a left front level control system sensor.
Tightening Specifications
Transmission to Engine
- A and B - : alignment bushings
- Replace the bolts - 1 through 5 -.
Transmission Mount Bracket to Transmission Bolts
- Replace the bolts.
Tighten the transmission mount bracket - 1 - to transmission bolts - arrows - to 60 Nm + 90° (1/4) additional turn.
Transmission Mount to Transmission Mount Bracket Bolts
- Replace the bolts.
Tighten the transmission mount - 2 - to transmission mount bracket bolts - arrows - to 60 Nm + 90° (1/4) additional turn.
• Install the transmission mount free of tension.