Transmission, Installing
Transmission, Installing
- Install the manual transmission and bevel box.
• Refer to "Transmission, Removing" to get a list of the special tools needed => [ Transmission, Removing ] Transmission, Removing.
• Replace the self-locking nuts and bolts.
• Replace bolts that were tightened with an additional turn.
• Install any cable ties that were loosened or cut off during removal at their same location.
• Clean the input shaft splines and (on used clutch plates) the hub splines. Remove any corrosion and apply a very thin coating of lubricant (G 000 100) on the splines. Then move the clutch plate back and forth on the input shaft until the hub moves freely on the shaft. Excess grease must be removed.
- Clean all threaded holes for self-locking bolts with a thread tap to remove any locking fluid residue.
- Make sure the alignment bushings 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 sleeve - arrows -.
- Check the release bearing for wear. Replace the slave cylinder with release bearing if necessary. Refer to => [ Slave Cylinder with Release Bearing ] Slave Cylinder With Release Bearing.
- Tighten the (T10346) and bracket with the bolt - 1 - to the bottom of the subframe.
- Use the center threaded hole meant for attaching the noise insulation cover.
- 1 - = M6 x 20 collar bolt or M8 x 20 collar bolt.
- Attach the (3300 A) to the (T10346).
- Place a cloth between the (3300 A) and the oil pan.
- Push the engine forward using the spindles on the (3300 A). Note the following points:
• 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.
To install the transmission the "02Q AWD", the (3282) must be equipped the (3282/62).
- 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 bolt (3282/29) instead of the mount - C -.
• Arm - A - is shorter than arm - B - due to the position of the transmission support.
• The mount must be attached to arm - A - (the shorter arm) with the bolt bolt (3282/29).
• This makes it easier to guide the shorter arm past the engine support - arrow - later.
- Place the transmission on the (V.A.G 1383 A).
- Align the adjustment plate so that it is parallel to the transmission.
- Install the (3282/29) into the hole in the transmission for the pendulum support bolt.
- Secure the adapter (VW 771/40) inside the threaded hole in the transmission housing as illustrated.
- Secure transmission on (3282) using bolt (M10 x 20) - A -.
The needle bearing drift - B - must be flush with the guide on the (3282) - arrow -.
- Place the (V.A.G 1383 A) under the vehicle. The arrow points in the drive direction.
• Pay attention to the lines when installing the transmission.
• In the case of vehicles with a vacuum diaphragm - arrow - and hose/line assembly, do not touch the components with the bevel gear.
The transmission support bolts - A - are loose (the transmission support installed through 11.09 is shown in the illustration).
- Using the spindles on the (3282) move the transmission so that it is just above the differential/bevel box.
- Carefully lift the transmission.
- Guide the transmission and bevel box past the subframe and with the right flange shaft past the (3300 A) - arrows -.
- Guide the transmission on the longitudinal member with the differential past the subframe - arrows -.
- Turn the transmission into it installed position using the spindles on the (3282).
- Guide the bevel box around the cover plate - A - and, if necessary, around the transmission support - B -.
• Be careful not to damage the Exhaust Gas Recirculation (EGR) vacuum regulator solenoid valve (N18) - arrow - and surrounding components.
- Line up the transmission and the engine and install it.
- Insert engine/transmission bolt - C - and tighten to tightening specification.
- Remove the (3300 A) and (T10346).
- Install the bolts that connect the engine to the transmission - 1 through 3 - and tighten them to the tightening specification.
- Remove the (3282) after the transmission is bolted to the engine at the bottom.
- Install the upper engine/transmission connecting bolts and tighten them to the tightening specification.
- Attach the gearshift lever to the transmission gearshift shaft. Tighten the nut to the tightening specification - item 17 - => [ (Item 17) Self-Locking Nut ] Shift and Selector Cables Overview.
- Install the relay lever together with the cable retainer.
- Attach the bracket - 1 - with the new hex bolts to the transmission - arrows - and tighten them to the tightening specification.
- Align the engine/transmission in its installed position. Lift it until the bracket - 1 - is in complete contact with the left subframe mount - 2 -.
- Install the new hex bolts - arrows - of the left subframe mount - 2 - in the bracket - 1 - and tighten to the tightening position.
- Attach the Ground (GND) cable to the bracket - 1 -, if equipped.
• Install the engine/transmission mount free of tension.
Only remove the (10-222 A) when all the subframe mount bolts are tightened to the specification.
- Attach the bevel gear transmission mount to the engine and bevel gear. Follow the tightening sequence when installing the bolts - arrows 1, 2 and 3 -.
The bolt heads may be different from those shown in the illustration.
Vehicles with a Vacuum Diaphragm from 11/09 - arrow 1 -
From 11/09, a brace - arrow 2 - is installed under the vacuum diaphragm - arrow 1 - at the top of the transmission support (gradual introduction).
- Attach the bevel box transmission support to the engine and the bevel box. Pay attention to the tightening sequence for the bolts - A and B -.
• The bolt - C - must be screwed in.
Continuation for All
- Install the drive axles.
- Attach the drive axle heat shield to the bevel box - arrows -.
- Install the left front level control system sensor (G78) in the transverse link, if equipped.
- Install the pendulum support.
- Attach the driveshaft with the flexible disc to the bevel box flange - arrows -.
• There are threaded inserts (for example "Heli-Coil(R)") in the pendulum support fastening holes.
• How to recognize: Shoulder at the first thread - arrow -.
• Be sure to use the correct bolts and tightening specification.
- Connect the connector - 1 - to the oil level thermal sensor (G266).
- Install the air shroud - arrow - and coolant fans.
- Install the left charge air hose - arrow 1 - and - arrow 2 -.
- Attach 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 on the starter and attach the connectors and the cables to the starter.
- Secure the Ground (GND) cable (if equipped) - 1 - to the upper starter bolt.
- Connect the connector - 2 - to the back-up lamp switch (F4).
- Push the hose/line assembly or pipe - A - into the bleeder/slave cylinder to the stop and push the clamp - arrow - downward.
- Pull on the line to make sure it is secure.
- Remove the (3094) from the hose/line assembly or supply hose.
- Bend the supply hose back into its original shape after removing the (3094).
- Bleed the clutch mechanism. Refer to => [ Clutch System, Bleeding ] Procedures.
- Make sure the vacuum hose for the brake system is installed correctly.
- Attach the cable mounting bracket to the transmission and tighten the bolts and nuts - arrows - to the tightening specification - items 6 and 10 - => [ (Item 6) Bolt ] Shift and Selector Cables Overview and => [ (Item 10) Nuts ] Shift and Selector Cables Overview.
- Install the selector cable in the cable retainer.
- Apply a small amount of grease on the pins - arrow - for the gearshift lever - 2 -.
For the correct grease allocation, refer to the Parts Catalog.
- Replace the lock washer - 1 - each time it is removed.
- Adjust the gearshift mechanism. Refer to => [ Shift Mechanism, Adjusting ] Adjustments.
- Install the battery tray and the battery.
- Secure the lines - A - to the bracket - B -.
- If removed, install the air filter housing.
- Install the engine cover if necessary.
- Connect the battery and then complete the steps after connecting the battery.
- Check the transmission fluid level inside the manual transmission. Refer to => [ Transmission Fluid, Checking ] Service and Repair.
- Check axle oil in the bevel box. Refer to => [ Axle Oil in Bevel Box, Checking or Filling ] Procedures.
- Install the lower section of the left and right front wheel housing liners..
- Attach the noise insulation.
- Check the headlamp adjustment if the vehicle has a left front level control system sensor (G78).
Tightening Specifications
Transmission to Engine
- A -: Alignment sleeves for centering
Install the Transmission Mount.
Allocation of bolts
The following assembly sequence must be followed when installing the transmission mount:
- Hand-tighten all bolts.
- Tighten the bolts - arrows 2 and 3 - to 40 Nm.
- Tighten the bolts - arrows 1 - to 40 Nm.
Vehicles with a Vacuum Diaphragm from 11/09 - arrow 1 -
From 11/09, a brace - arrow 2 - is installed under the vacuum diaphragm - arrow 1 - at the top of the transmission support (gradual introduction).
Allocation of bolts
The following assembly sequence must be followed when installing the transmission mount:
- Hand-tighten all screws.
- Tighten the bolts - A - to 40 Nm.
- Tighten the bolts - B - to 40 Nm.
Continuation for All
Transmission Bracket - 1 - to Transmission.
- Replace the bolts.
Bolts - arrows -: 60 Nm + 90° additional turn
Transmission to Body
- Replace the bolts.
Bolts - arrows -: 60 Nm + 90° additional turn
• Install the engine/transmission mount free of tension.