Transmission, Installing

Transmission Installing





Notes:
^ Before installing transmission, press clutch release lever toward transmission housing and secure with assembly pin, assembly bolt or Me x 35 bolt. Remove after transmission has been installed. The hole will then be plugged by the 3rd cable support bracket securing bolt.





^ When replacing the transmission, transfer the speedometer sender (see illustration), the gear selector lever and the relay lever to the new transmission.

- Clean input shaft splines and lightly grease with GOOD 100 grease.
- The clutch plate must be able to slide freely in both directions on the input shaft
- Check whether dowel sleeves for aligning engine/transmission are fitted in cylinder block. Install if necessary.





- Ensure that the intermediate plate is correctly positioned on engine.
- Bolt support rail VW 457/1 to both pendulum support securing holes on subframe.
- Spacers (total width 6 mm) must be inserted between subframe and support rail VW 457/1.
A - Hexagon bolts M 8 x 25 (2 bolts)
- Fit support 3300 A and secure in place (arrows).
- Press engine forward carefully.

Notes: Do not damage power-assisted steering pipe.

- Assemble transmission jack with transmission support 3282, adjustment plate 3282/8 for "O2A" transmission and support elements as follows:
- Place adjustment plate 3282/8 on transmission support 3282. (Adjustment plate only fits in one position).





- Align arms of transmission support according to holes in adjustment plate.
- Bolt on support elements - A - as shown on adjustment plate.
- Place transmission on transmission jack.





- Align adjustment plate and transmission parallel with one another and lock safety supports on transmission.
- Place transmission jack under vehicle. Arrow symbol - B - (Illustration No. V34 -2670) on adjustment plate points to front of vehicle.
- Incline transmission to left via the spindles of the transmission mounting 3282.
- Insert transmission.

Notes: Do not damage power- assisted steering lines.

- Install lower securing bolts for engine/transmission.





- Remove support 3300 A and support rail VW 457/1.
- Install transmission console - A - with new bolts (arrows).
- Install upper securing bolts for engine/transmission.
- Raise engine/transmission assembly via spindles on support bar 10-222A. - Align engine/transmission in installation position.





- Install new hexagon bolts (arrows - B -) on left side in transmission mounting.
- Fit transmission support (arrows - A -) to transmission.

Notes: Install engine/transmission support free of tension.

WARNING!: Do not remove support bar 10 222A until the bolts securing the left - hand transmission console have been tightened to the specified torque.





- Install pendulum support (arrows).
- Use new bolts for securing.
- Reconnect exhaust system.
- Install retainer for power - assisted steering pipe on transmission.





- If it was removed earlier, install small cover plate - A - behind right - hand drive flange (arrows).
- If it was removed earlier, install large cover plate for clutch.
- Fit drive axles to transmission.
- If it was removed earlier, install protective cap for right - hand inner constant velocity joint to engine.
- Install starter.





- Check transmission oil level.
- Install deadener pan below engine/transmission (if equipped).
- Install cover for engine.





- Install slave cylinder.
- Install transmission support at transmission (arrow A).





- Press gear selector cable onto selector lever on transmission and press gate selector cable onto relay lever (arrows).
- Install cable support bracket on transmission. If necessary, push hose onto cable support bracket.
- Attach reverse light connector (arrow 2). Attach all other electrical connections and Ground wires to transmission and to the engine/transmission securing bolts. - Attach connector to speedometer sender (arrow 1).





- Adjust gear selector mechanism.
- Install air cleaner housing (complete).
- Install battery tray and battery.
- Connect the battery.
- Enter anti - theft coding for radio - operating instructions.
- Using power window regulators, raise windows up to stop.
- Then activate window regulator switch again for 1 second in closed position to activate automatic toll booth window regulator function.
- Set clock.

Tightening torques





Transmission to engine

Vehicles with 4 Cyl. engine





1) Bolt with headless screw M8
A: Dowel sleeves for centering





Gearbox console -A- to transmission 50 Nm + 90°.





- Replace bolts.
Transmission to body
Bolts -A-25 Nm
Bolts -B-60 Nm + 90°
- Replace bolts - B -.





Rear transmission mounting
Bolts -A- 20 Nm + 90°.
Bolts -B- 40 Nm + 9O°.
- Replace bolts

Notes: Install engine/transmission mountings stress - free.

Drive axle to drive flange M8 40 Nm
Drive axle to drive flange M10 77 Nm
Flywheel cover plate 10 Nm
Selector cable support bracket to transmission 25 Nm