Transmission, Installing

Transmission, Installing

Perform the following:

- Clean any locking fluid residue from all threaded holes using a tap.

- 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 the transmission may make noises (loose rattling).

- Make sure the intermediate plate is engaged on the sealing flange and is pushed onto the alignment sleeves - arrows -.






- 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.

- Check the clutch release bearing for wear. Replace the clutch slave cylinder with release bearing if necessary. Refer to => [ Clutch Slave Cylinder with Release Bearing ] Clutch Slave Cylinder with Release Bearing.

To install the transmission the adjustment plate (3282/33) must be installed on the transmission support (3282).






- 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 pin (3282/29) in place on the adjustment plate - C -.

- Place the transmission on the engine-/gearbox 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 in the transmission for the pendulum support bolt.

- Install the adapter (VW 771/40) inside the threaded hole in the transmission housing as illustrated.






- 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 -.

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

• Pay attention to the wires and hoses when installing the transmission.

- Lift the transmission carefully.

• 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 - 2 - on the cylinder block.






- Change the position of the transmission using the spindles on the transmission support (3282) so that it does not come in contact with the longitudinal member - arrows -.






- Turn the transmission into it installed position using the spindles on the transmission support (3282).

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

- Insert the engine/transmission bolt - C - and tighten it to specification. refer to => [ Transmission to Engine Tightening Specifications ] Mechanical Specifications.






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

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






- 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. Refer to => [ Transmission to Engine Tightening Specifications ] Mechanical Specifications.

- Install the transmission shift lever to the transmission gear shift shaft, refer to => [ Transmission Shift Lever, Installing ] Shift Mechanism Overviews and tighten the nut to specification. See - item 6 - in => [ Shift and Selector Cables ] Shift Mechanism Overviews.

• Grease the bearing areas and sliding surfaces on the relay lever and transmission shift lever. Refer to => [ Relay Lever, Lubricating ] Shift Mechanism Overviews and => [ Transmission Shift Lever, Lubricating ] Shift Mechanism Overviews. For the correct grease, refer to the Parts Catalog.

- Install the relay lever and cable retainer - arrow 2 - all the way into the gear shift cover.






- Install the clip - arrow 1 - and make sure it is locked into place.

- Install the transmission mount bracket - 1 - to the transmission with bolts - arrows - and tighten them to specification. Refer to => [ Engine and Transmission Mounts and Brackets Overview ] Service and Repair.






- Align the engine/transmission in its installed position. Lift it until the transmission mount bracket - 1 - is in complete contact with the transmission mount - 2 -.






Risk of damaging threads in the transmission mount bracket by installing the bolts crooked.

• The transmission mount bracket - 1 - and the transmission mount support arm - 2 - must be absolutely parallel to each other before installing the bolts - arrow -. If necessary, lift the back of the transmission using the engine-/gearbox jack.

• Install the transmission mount free of tension.

- Install new transmission mount - 2 - to transmission mount bracket bolts - arrows - and tighten them to specification. Refer to => [ Engine and Transmission Mounts and Brackets Overview ] Service and Repair.

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

- Install the flywheel cover plate - A -, if equipped - arrows -. Refer to=> [ Transmission to Engine Tightening Specifications ] Mechanical Specifications.






- Install the drive axles to the transmission.

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






- Install the subframe with steering gear.

• There are threaded inserts (for example "HeliCoil") in the pendulum support bolt holes in the transmission.

• How to recognize: The shoulder at the first thread - arrow -.






• For the correct bolts and tightening specifications.

- Secure the pendulum support to the transmission using new bolts.






- Connect the connector - 1 - to the oil level thermal sensor (G266).






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

- Install the starter and tighten the lower bolts.

- Attach the bracket to the lower starter bolt.

- Install the starter bolt and then connect the connector and wires to the starter.

- Attach the ground strap - 1 - to the top starter bolt.






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

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






- Pull on the hose/line assembly or line to make sure it is secure.

- Remove the hose clamp up to 25 mm dia. (3094) from the hose/line assembly or supply hose.

- Bend the supply hose back into its original shape after removing the hose clamp up to 25 mm dia. (3094).

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

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

- Attach the cable bracket to the transmission and tighten the bolts and nut - arrows - to specification. See - items 13 and 16 - in => [ Shift and Selector Cables ] Shift Mechanism Overviews.






- Apply a small amount of grease onto the transmission shift lever pin - arrow -.






• For the correct grease allocation, refer to the Parts Catalog.

- Secure the shift cable - 2 - to the transmission shift lever with a new lock washer - 3 -.

- Install the selector cable into the cable retainer on the relay lever.

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

- Install the plenum chamber cover.

- Install the lock carrier trim and the bolts - arrows - for the left and right front end brackets.






- Install the battery tray and the battery.

Vehicles with a Diesel Engine:






- Attach the charge air hose to the turbocharger and secure it with the bolt - 2 -.

- Attach the crankcase ventilation hose - 1 - and clip the vacuum hoses to the charge air hose - arrows -.

- Connect the crankcase ventilation hose connection - 1 -.

Continuation for all Vehicles:

- Install the air filter housing.

- Install the engine cover.

- Connect the battery and follow the procedure regarding what to do after connecting the battery.

- Check the transmission fluid level. Refer to => [ Transmission Fluid, Checking ] Service and Repair.

- Install the left front wheel housing liner.

- Install the noise insulation.

- Install the wheel.