Transmission, Installing

Transmission, Installing

• 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 were tightened to an additional 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 fluid residue from all threaded holes using a tap.

- Check whether there are alignment sleeves for the engine to 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 => [ Clutch Slave Cylinder with Release Bearing ] Service and Repair.

- 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 the 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 - 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 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 pins 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 on the transmission for the pendulum support bolt.

- Secure the adapter for VW 771 slide hammer (VW 771/40) in the threaded hole in the transmission housing as illustrated.






- Secure the transmission to 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-/gearbox 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.

- Rotate the transmission upward near the rear differential and downward near the 6th gear by 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 cylinder block bolt flange - 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 to transmission bolt - C - and tighten it to specification. Refer to => [ Transmission to Engine Tightening Specifications ] 02Q Manual Transmission.






- Install the lower engine to transmission bolts and tighten them to specification. Refer to => [ Transmission to Engine Tightening Specifications ] 02Q Manual Transmission.

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

- Install the engine to transmission bolt - arrow - and tighten it to specification. Refer to => [ Transmission to Engine Tightening Specifications ] 02Q Manual Transmission.






- Remove the transmission support (3282) after the transmission is bolted to the engine at the bottom.

- Install the upper engine to transmission bolts and tighten them to specification. Refer to => [ Transmission to Engine Tightening Specifications ] 02Q Manual Transmission.

- Attach the transmission shift lever to the gear shift shaft. Refer to => [ Installing the Transmission Shift Lever ] Shift and Selector Cables Overview and tighten the nut to specification, see - item 17 - in the => [ Shift and Selector Cables Overview ] Shift and Selector Cables Overview.

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

- Install the transmission mount bracket - 1 - with new bolts, to the transmission - arrows - and tighten them to specification. Refer to => [ Transmission to Engine Tightening Specifications ] 02Q Manual Transmission.






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






- Install the new transmission mount - 2 - to transmission mount bracket bolts - arrows - and tighten them to specification. Refer to => [ Transmission to Engine Tightening Specifications ] 02Q Manual Transmission.

• Install the engine and transmission mount free of tension.


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 ] 02Q Manual Transmission.






• There are threaded inserts (for example, a "Heli Coil") in the pendulum support bolt holes.

• How to recognize: There is a shoulder at the first thread - arrow -.






• For the correct bolts and tightening specifications, refer to => Suspension, Wheels, Steering 40 Specifications.

- Install the pendulum support.






- Install the drive axles.

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






- Install the left coupling rod.

- Connect the oil level thermal sensor connector - 1 -, if equipped.






with a Gas Engine






- Install the front exhaust pipe - arrow - to he turbocharger.

with a Diesel Engine

- Connect the exhaust system at the double clamp - arrows -.






- Install the exhaust system suspended mount and bolts - arrows - to the subframe.






Continuation for All

- Install the fan shroud - arrow - and coolant fans.






- Install the charge air pipe to the engine.

- Install the left charge air hose - 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 wires to the lower starter bolt.

- Install the top stud bolt to the starter and attach the connector and the cables to the starter.

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






- Connect the backup lamp switch connector - 2 -.

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






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

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

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

- Attach the cable bracket to the transmission and tighten the bolts/nut - arrows - to specification, see - items 6 and 10 - in the => [ Shift and Selector Cables Overview ] Shift and Selector Cables Overview.






- 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 plenum chamber cover.

- Install the radiator grille.

- Install the battery tray and the battery.

- Install the air filter housing.

- Install the engine cover.

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