Transmission, Installing

Transmission, Installing

Install in reverse sequence; note the following points:

- All threaded bores, in which self-locking bolts are threaded, must be cleaned of locking fluid residue using a thread tap.

- Replace self-locking bolts and nuts.

- Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of Lubricant (G 000 100) on splines. Do not lubricate guide sleeve.

The clutch plate must be able to easily slide back and forth on the input shaft.

- Check clutch release bearing for wear, replace if necessary.





- Release bearing with loose plastic ring - arrows -, servicing if necessary => [ (Item 1) Release bearing ] 02XA Transmission.

• If running mark on plastic ring is deeper than 0.8 mm, release bearing must be replaced

- Check if the alignment sleeves for centering engine/transmission are in the cylinder block, and install if necessary.

- Place intermediate on alignment sleeves on engine flange.

- Before installing transmission, tie electrical wiring and bracket to one side so that it cannot be trapped between engine and transmission.

- Lightly coat plunger contact surfaces at clutch return lever - arrow B - with Copper Grease (Z 381 351 TE ).





- Lift transmission until clutch slave cylinder can be installed with hose/line assembly bracket.

- Guide clutch slave cylinder - 1 - into transmission housing mounting hole without great sideways movement from working direction of plunger - arrow A - and insert in recess - arrow B - in clutch return lever - 3 -.

• If the clutch slave cylinder - 1 - is guided in angled, there is a risk that the plunger - arrow A - may be guided past the clutch release lever - 3 -.

- Tighten the slave cylinder with a new bolt - arrow -. Tightening specification => [ (Item 13) Internal hex bolt, 23 Nm ] 02XA Transmission.





CAUTION!
Carefully actuate the clutch pedal after installing the clutch slave cylinder. If an abnormally difficult pressure point is noticed when depressing the clutch pedal, do not depress the clutch pedal any further. The plunger of the clutch slave cylinder was probably guided past the clutch release lever. Beyond a pedal force of approximately 300 N, clutch slave cylinder is destroyed.

- Install transmission, observing clearance at drive axles.

- Install the engine/transmission bolts - arrow A - and - arrow B -.





- Starter, installing. Refer to => Starting and Charging Starting and Charging

- Carefully lower the transmission just a little using the Engine/Transmission Jack (V.A.G 1383 A).

- Tighten the upper engine/transmission bolts - arrow 1 - and - arrow 2 - if possible.





- Attach all electrical wires to the transmission - arrow A through C -, if equipped.





- Install the selector shaft lever and tighten the nut - arrow -. Tightening specification => [ (Item 24) Cap nut, 20 Nm ] Selector Mechanism Assembly Overview.





- Install push rod - 1 - by tightening socket head hex bolt. Tightening specification => [ (Item 13) Bolt, 40 Nm ] Selector Mechanism Assembly Overview.





- Tighten selector rod connecting rod - 2 -. Tightening specification => [ (Item 10) Bolt, 20 Nm ] Selector Mechanism Assembly Overview.

- Connect right Back-Up Light Switch connector - arrow - to transmission.





- Install the Engine Speed (RPM) Sensor (G28) on the transmission on the left side, if equipped.





- Lift the transmission using the Engine/Transmission Jack (V.A.G 1383 A).





- Secure the tunnel crossmember to the body with the new bolts - 2 - and - 3 - hand-tight.

- Attach the tunnel crossmember to the transmission mount - 4 -.

- Carefully lower Engine/Transmission Jack (V.A.G 1383 A) and set aside.

- Drive axles - 1 -, installing on flange shafts refer to => Steering and Suspension Steering and Suspension

- Clean threaded holes for drive axle bolts of all locking compound residue. Cleaning can be performed with a thread tap.

- Attach the drive axle on the transmission - arrows -.





- If equipped, install driveshaft heat shield - arrows -.





Vehicles with 6-cylinder gasoline engine:

• Engine slightly pretensioned with Engine Support Bridge (10 - 222 A).

- First remove front bolts - 2 - and - 3 - at left and right subframe. Then remove bolts - 1 -.





- Lower front subframe.

- Tighten three lower engine/transmission bolts - arrows -.





- Replace the front subframe bolts - 1 -, - 2 - and - 3 - on both sides of the vehicle.





The subframe must be attached to the body using the Testing Mandrel (3393) before tightening.





• Hole - 1 -, hole - 2 - in the subframe and hole - 3 - in the aluminum bracket must align on both sides.

• This replaces a subsequent vehicle alignment if the holes - 1 - and - 2 - were aligned prior to the repair.

- Tighten engine mount nuts - 1 -.





Cabriolet with 4-cylinder engine:

- Lift engine a little with spindles.





- Tighten lower engine/transmission bolts - arrows -.





- Lower engine again.

- Tighten torque support - arrows -.





- Tighten engine mount nuts - 1 -.





All Vehicles

- Subframe and tunnel crossmember, tightening. Refer to =>
Steering and Suspension Steering and Suspension

- Install the exhaust system and align it free-of-tension.

- Check adjustment of shift mechanism and adjust if necessary. Refer to => [ Shift Mechanism, Adjusting ] Adjustments.

- Check gear oil level in manual transmission. Refer to => [ Manual Transmission, Checking Gear Oil Level ] 02XA Transmission.

- Heed appropriate instructions for work to be performed following battery connection.

- Perform vehicle alignment if necessary.

• If a fixation to body with Test Mandrels (3393) was performed before removal and installation of subframe (before tightening screws), vehicle alignment is not necessary.

• If no fixation was performed for both Test Mandrels (3393) could not be completely guided into holes, a vehicle alignment must be carried out.

Tightening Specifications

• The torque specifications apply only to lightly greased, oiled, phosphated, or black-finished nuts and bolts.

• Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant.

• Do not use degreased parts.

• Tolerance for torque specification ± 15%.

Mounting, 1.8L gasoline engine to transmission









Mounting, 2.0L gasoline engine to transmission









Mounting 6-cylinder 3.0L gasoline engine to transmission









Mounting 6-cylinder 3.2L FSI gasoline engine to transmission