Transmission, Installing
Transmission, Installing
Tightening specifications for securing engine/transmission
Other Tightening Specifications
Transmission, Installing
Install in reverse sequence; note the following points:
• When performing repairs, replace self-locking nuts and bolts.
• Always replace bolts that are secured with tightening torque as well as seals, gaskets and O-rings.
• Secure all hose connections with hose clamps of the same type as those equipped by the factory.
• All cable ties that are opened or cut open during removal must be replaced in the same positions during installation.
• Clean the input shaft splines and on a used clutch plate, the hub splines, remove corrosion and apply only a very thin coating of grease (G 000 100) onto the splines. Then move clutch plate back and forth on input shaft until the hub moves freely on the shaft. Excess grease must be removed.
• If the transmission is being replaced, switch over the transmission shift lever.
• All threaded bores, in which self-locking bolts are threaded, must be cleaned of locking fluid residue using a thread tap.
• Check if the alignment sleeves for centering engine/transmission are in the cylinder block, and install if necessary.
• If alignment sleeves are not installed, difficulty in shifting, clutch problems and possibly noises from the transmission (loose gear chatter) may develop.
- Make sure that intermediate plate is engaged on sealing flange and has been slid on to centering sleeves - arrows -.
- Check release bearing for wear. Replace slave cylinder with release bearing if necessary. Refer to => [ Clutch Slave Cylinder with Release Bearing ] Service and Repair.
- Check the centralization of the clutch plate. Refer to => [ Clutch, LuK ] Clutch, LuK.
- Carefully raise transmission and move it into installation position using (3282).
- Align transmission to engine and install.
- Tighten transmission and starter on engine to tightening specifications.
- Install left drive axle - 1 -.
- Remove (3300 A) and (T10036).
Metal Relay Lever - 1 -
- Insert the relay lever - 1 - and secure it with a locking washer - arrow -.
Plastic Relay Lever
- Insert the relay lever together with the cable retainer.
• The tab - arrow 1 - secures the relay lever
• Make sure it engages securely.
• The cable retainer must be behind the tab - arrow 2 -.
Continued for All Vehicles
- Attach the bracket to the transmission with the new bolts - arrows -. Tightening specification. Refer to => [ Subframe Mount Overview ] Description and Operation.
- Align engine/transmission in installed position. To do so, raise far enough until bracket - 1 - makes contact at left subframe mount - 2 - completely.
• To prevent the threads in the mount from being damaged, the transmission mount and bracket must be parallel to one another.
- Fasten the bracket - 1 - to the left assembly mounting - 2 -, using new hex bolts - arrows -. Tightening specification => [ Subframe Mount Overview ] Description and Operation.
Do not remove (10 - 222 A) until all bolts for left assembly mounting have been tightened to tightening specification.
- Install pendulum support with new bolts - 1 through 3 - => [ Install the Pendulum Support ] Pendulum Support. Tightening specifications => [ Subframe Mount Overview ] Description and Operation.
- Check the adjustment of the subframe mounting, adjust if necessary.
- Tighten catalytic converter on turbocharger - arrows -.
- If present, install small flywheel cover plate - A -.
- Completely install left and right drive axles to transmission.
- Install the right drive axle heat shield - arrows -.
- Install bracket - 1 -.
- Connect the connector - 2 - on the back-up lamp switch (F4).
- Install fan shroud - arrows - and connect electrical connector - 1 -.
- Install air guide hose. Ensure securing clip - arrow - engages audibly in retaining tab - A -.
- Install a new sealing ring - 3 - on hose/line assembly - 4 - with some brake fluid.
- Slide hose/line assembly - 4 - into breather - 1 - until securing clip - 2 - engages audibly.
- Verify by pulling on hose/line assembly.
- Bleed the clutch system. Refer to => [ Clutch System, Bleeding ] Service and Repair.
- Install the cable mounting bracket on the transmission - arrows -.
- Apply a small amount of grease (G 000 450 02) to the transmission shift lever - 1 - pins - arrow -.
- Slide the selector cable onto the pin - arrow - and secure with the lock washer - 3 -.
Metal Relay Lever - 2 -
- Apply a small amount of grease (G 000 450 02) to the relay lever - 2 - pin - arrow -.
- Slide the selector cable onto the pin - arrow - and secure with the lock washer - 4 -.
Plastic Relay Lever - 2 -.
- Insert the selector cable in the cable retainer.
Continued for All Vehicles
- Adjust shift mechanism, refer to => [ Shift Mechanism, Adjusting ] Adjustments.
- Tighten Ground (GND) cable - 1 -.
- Install battery carrier and battery.
- Install engine cover.
- Install complete air filter housing.
- Check gear oil level in manual transmission. Refer to => [ Manual Transmission, Checking Gear Oil Level ] Service and Repair.
- Install the left front wheel housing liner attachments - 1 through 3 -.
Audi A3
- Install the noise insulation in the center attachments - 1 through 2 -.
Audi A3 Cabriolet
- Install the noise insulation frame - arrow -.
- Install the center noise insulation - 1 -.
Continued for All Vehicles
Tighten left drive axle with a new bolt - 2 -.
• The wheels must not touch the floor when tightening the drive axle; otherwise, the wheel bearing can be damaged.