Installing

Transmission

Special tools, testers and auxiliary items required

• Engine Support Bridge (10 - 222 A)

• Engine Support Feet (10 - 222 A/ 8)

• Additional Hooks ( 10 - 222 A/2)

• Engine Support Adapter (10 - 222 A/3)

• Adapter (10 - 222 A/16)

• Transmission Support (3282)

• Shackle (10-222 A/12)

• Adjustment Plate (3282/39)

• Engine/Transmission Jack (V.A.G 1383A)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Transmission Support Jig (3336)

• Grease for Clutch Plate Splines (G 000 100)

Installing

• Refer to "Removing" to get a list of the special tools needed. Refer to => [ Transmission ] Transmission.

Pay attention to the following list for the subject -"Transmission Fluid, Checking and Filling"






- Clean all threaded holes with a thread tap to remove any locking fluid residue.

- Always replace self-locking nuts and bolts.

- 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 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 splines (G 000 100).

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

To install the transmission, the transmission support (3282) must be equipped with the adjustment plate (3282/39).

- Align the arms on the transmission support so that they match up with the holes in the adjustment plate.

- Install the mounting elements - A and C - to the adjustment plate as illustrated.





- Place the transmission on the engine/transmission jack.

- Align the adjustment plate so that it is parallel to the transmission.

- Install the adjustment plate into the hole on the transmission for the pendulum support bolt.





- Position the engine/transmission jack under the vehicle. The - arrow symbol B - on the adjustment plate points in direction of travel.

- Using the spindles of the transmission support (3282), screw the transmission downward in the area of the differential.

- Then carefully lift the transmission, when doing so, guide the right flange shaft - A - in the area of the flywheel/intermediate plate as shown.





- Using the spindles of the transmission support (3282), screw the transmission upward in the area of the differential.

- Raise the transmission up to the engine.

- Push the engine forward slightly with the help of a 2nd technician.

- Align the transmission with the engine and install it.

- Install the lower engine/transmission bolts and tighten to specification. Refer to => [ Tightening Specifications ]. Tightening Specifications

- After the transmission is attached to the engine, remove the engine/transmission jack from the transmission.

- Install the small cover plate, if equipped, behind the right flange shaft - A - - arrows -.





- Install the upper engine/transmission bolts and tighten them to specifications. Refer to => [ Tightening Specifications ]. Tightening Specifications

- Attach the transmission mount bracket - A - with new bolts to the transmission - arrows - and tighten them to specifications. Refer to => [ Tightening Specifications ]. Tightening Specifications





- Use the engine support bridge (10 - 222 A) spindles to align the engine/transmission in the installed position.





- Install new bolts - arrows - for the transmission mount and tighten them to specifications. Refer to => [ Tightening Specifications ]. Tightening Specifications


Only remove the engine support bridge (10 - 222 A) when the bolts for the left and right mounts are tightened to specification.

• Install the transmission mounts free of tension. Refer to => [ Tightening Specifications ]. Tightening Specifications

- Install the slave cylinder and tighten the bolts - arrows B - to specification, refer to - item 9 - in => [ Clutch Release Mechanism ] Service and Repair.





- Install the transmission support and bolts - arrows A - and tighten them to specification. Refer to => [ Tightening Specifications ]. Tightening Specifications

- Attach the drive axles to the transmission.

- Install the drive axle heat shield and bolts - arrows -, if equipped.





- Install the pendulum support using new bolts - arrows A, B and C -.





- Assemble the exhaust system and then attach the suspended mount to the subframe.

- Install the brace - 1 - to the transmission and tighten the bolt - arrow - to specification.





- Connect the connector - 1 - to the backup lamp switch (F4).





- Install the starter, connect the connector - arrow 2 - and attach the wire - arrow 3 -.

- Attach the ground cable to the upper engine/transmission bolt.

- Attach the bracket - B - to the transmission.





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

- Install the cable bracket to the transmission and tighten the bolts - arrows - to specification. See - item 6 - in => [ Shift and Selector Cables ] Shift Mechanism Overviews.

- Install the shift lever - A -.





- Tighten the nut - arrow 4 - to specification, see - item 18 - in => [ Shift and Selector Cables ] Shift Mechanism Overviews.

- Apply a small amount of grease to the transmission shift lever - A - pin.

For the correct grease for the gearshift mechanism, refer to the Parts Catalog.

- Connect the shift cable with the transmission the shift lever - arrow 1 -.

With a Metal Relay Lever:

- Install the relay lever - B - and secure it with the lock washer - arrow 3 -.

- Apply a small amount of grease to the relay lever - B - pin.

For the correct grease for the relay lever the Parts Catalog.

- Install the selector cable to the relay lever - arrow 2 -.

With a Plastic Relay Lever:

- Install the relay lever with the cable retainer. Refer to => [ Plastic Relay Lever ] Plastic Relay Lever.

Continuation for All:

- Adjust the shift mechanism. Refer to => [ Shift Mechanism, Adjusting ] Adjustments.

- Install the battery tray, the battery and cover.

- Install the engine cover and air filter housing.

- Connect the battery and complete the steps after connecting the battery.

- Install the lower part of the left front wheel housing liner..

- Install the noise insulation.