Transmission, Installing

Transmission, Installing

=> [ Tightening Specifications ]

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

• Replace the self-locking nuts and bolts.

• Replace bolts that have been tightened to a torque angle.

• Reinstall cable ties that were loosened or cut off during removal at the same locations during installation.

• Clean the input shaft splines and (on used clutch plates) the hub splines, remove corrosion and apply a very thin coating of grease for clutch plate splines (G 000 100) to the splines. Then move the clutch plate back and forth on the transmission input shaft until the hub moves freely on the shaft. Excess grease must be removed.

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

- Make sure the alignment sleeves for the engine to transmission are installed in 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 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 => [ Clutch Release Mechanism Overview ] Clutch Release Mechanism Overview.

- Tighten the bracket (T10346) with the bolt - 1 - in the right threaded hole in the subframe.

- Install the bracket (T10346) in the same angled position as the engine.

- 1 - = M6 x 20 collar bolt

- Secure the engine support device (3300 A) to the bracket (T10346).






- 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 - 2 - must not touch the refrigerant line - 1 - - arrow -.

• The generator must not touch the refrigerant line.

• The pressure pipe must not touch the radiator.

Align the transmission support (3282) with the adjusting plate (3282/60) when installing the "0A6" transmission.

- Install the transmission support (3282) onto the engine/transmission jack (V.A.G 1383 A).

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

- Install the support elements - A - as illustrated on the adjusting plate.






- Install the mount - C - = pin (3282/34).

- Place the transmission on the engine/transmission jack (V.A.G 1383 A).

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






- Place the engine/transmission jack (V.A.G 1383 A) under the vehicle. The arrow points in the drive direction.

- Install the pin (3282/34) into the hole on the transmission for the pendulum support bolt.






- Tilt the transmission to the left by adjusting the spindles on the transmission support (3282).

- Then carefully raise the transmission, when doing so pay attention to the longitudinal member.






• Pay attention to the wires when installing the transmission.

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






- Remove the engine support device (3300 A) and the bracket (T10346).

- Install the engine/transmission bolt - arrow - and tighten it to specification. Refer to => [ Tightening Specifications ].






- After the transmission is bolted to the engine at the bottom, remove the transmission support (3282) from the transmission.

- Align the engine/transmission into its installed position. To do so, lift it just enough so that the transmission completely touches the transmission mount.

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







Only remove the engine support bridge (10-222 A) when all the transmission mount bolts are tightened to specification.

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






- Install the starter - 3 -.






- Connect the connector - 2 - to the backup lamp switch (F4).

Connect the ground cable - 1 - to the transmission. Refer to => [ Tightening Specifications ].

- If there is a bracket - 1 - installed, attach the ground cable with a nut - 2 -.






- Replace the circlip - arrow A - and the O-ring - arrow B - on the stub shafts.






Lubricate the stub shaft splines with grease for clutch plate splines (G 000 100).

Install the drive axles.

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






- Install the pendulum support.






- Assemble the exhaust system.

- If equipped, install the left front level control system sensor (G78).






- Install the fan shroud - arrow - and fans.






- Install the charge air hose and clamps - arrows 1 and 2 - , and if it was removed earlier, install the charge air pipe to the engine.






- Push the hose/line assembly or pipe - A - into the breather assembly/slave cylinder up to the stop and push the clip - arrow - inward.






- Pull on the line to make sure it is tight.

- Remove the hose clamp up to 25 mm dia, (3094) from the supply hose.






- After removing the hose clamp up to 25 mm dia. (3094) , bring the supply hose back to its original shape.

- Bleed the clutch system. Refer to => [ Clutch System, Bleeding ] Clutch System, Bleeding.

- Make sure the vacuum hose for the brake system is installed correctly.

- Install the cable bracket to the transmission and tighten the bolts - arrows - to specification. Refer to => [ Tightening Specifications ].






- Install the transmission shift lever - 2 - and then tighten the nut to specification, see - item 15 - in => [ Shift and Selector Cables ] Shift Mechanism Overviews.






- Apply a small amount of grease to the pin - arrow - on the transmission shift lever - 2 -.

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

- Install the shift cable. Replace the lock washer - 1 - after each disassembly.

- Install the relay lever with the cable retainer. Refer to => [ Installing the Relay Lever and Cable
Retainer ] Shift Mechanism.

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

- Install the battery tray and the battery.

- Install the air filter housing, if it was removed earlier.

- Install engine cover if necessary.

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

- Check the transmission fluid level. Refer to => [ Transmission Fluid Level, Checking ] Procedures.

- Install left front wheel housing liner.

- Install the noise insulation.

- Install the wheels.

- Check the headlamp adjustment on vehicles with a front level control system sensor.

Tightening Specifications

Transmission to Engine










- A and B -: Alignment sleeves

Transmission to Body





- Replace the bolts.

Tighten the bolts - arrows - to 60 Nm + 90° (1/4) additional turn.

• Install the engine/transmission mount free of tension.

Ground Cable Bolt/Nut to Transmission






- Tighten the ground cable - 1 - bolt/nut to 20 Nm

• Ignore - 2 and 3 -.