Transmission, Installing
Transmission, installing, 01A, 5 SPD. M/T (AWD)
^ Clean splines of input shaft and lightly grease with grease G 000 100.
Clutch disc must be able to be moved back and forth on input shaft.
^ Check clutch release bearing for wear and replace if necessary.
^ Make sure centering sleeves for engine to transmission are installed in cylinder block. Install if necessary.
^ If installed, make sure intermediate plate is seated properly at engine.
^ Assemble transmission jack with transmission support 3282, adjustment plate 3282/10 for "012"/"01A" transmission and support elements as follows:
^ Place adjustment plate 3282/10 on transmission support 3282 (adjustment plate fits in only one position).
^ Align transmission support arms to correspond with holes in template.
^ Screw in attachments - A -, as depicted on adjustment plate.
^ Place transmission onto transmission support.
^ Align adjustment plate and transmission parallel to each other.
^ Secure safety support - arrow -on transmission.
^ Set transmission jack under vehicle, arrow symbol - B - (Fig. V34-2583) on adjustment plate points in direction of travel/vehicle.
^ Lift transmission until clutch slave cylinder with mounting bracket for line/hose can be installed - arrow -.
^ Install engine speed sensor on clutch housing.
^ If installed, place intermediate plate between transmission and engine onto engine alignment bushings.
^ When inserting transmission, make sure that flanges for drive axles are located in transmission flange shafts.
^ Insert transmission.
^ When inserting, push up engine slightly at torque supports (in direction of - arrow -) with a second technician if necessary.
^ Screw in bolts for engine/transmission mount at bottom and for starter; insert starter.
Vehicles with 4-cylinder engine and 6-cylinder engine
^ Bolt right transmission support with bonded rubber bushing to transmission and subframe - arrows A -.
^ Bolt left transmission support to bonded rubber bushing - arrow B - (shown here in conjunction with 6-cylinder engine).
Note:
^ Install engine/transmission beating free of tension.
Continued for all vehicles
^ Install drive axles on flange shafts
^ Install cover plates over right drive axle - arrow 1 - and - arrow 2 -.
^ Install cover plate, if present, over left drive axle.
^ Push shift rod on so that securing bolt fits into recess of shift rod.
^ Secure shift rod - arrow A - first.
^ Secure pivot rod to transmission - arrow B -.
(Depicted here on manual transmission "012"/"01W").
^ Install front exhaust pipe with catalytic converter.
^ Install driveshaft.
^ Adjusting driveshaft.
^ Install sound insulation pan on bottom of engine/transmission, if present.
^ Connect connector for back-up lights - arrow B -.
^ Connect connector for Speedometer Vehicle Speed Sensor (VSS) G22 - arrow A -.
^ Install connecting bolts for engine/transmission.
^ Bolt expansion tank for cooling system.
^ Install intake hose on Mass Air Flow (MAF) Sensor G70.
^ Then install intake air scoop.
^ Install intake manifold cover.
^ Connect battery Ground (GND) strap.
Note:
^ For vehicles equipped with coded anti-theft radio, note code.
^ Check gear oil.
^ Adjust shift mechanism: Shift lever must be pushed down to select reverse gear.
^ Adjust shift mechanism: Shift lever cannot be pushed down to select reverse gear.
Tightening torques
Transmission to engine
Vehicles with 4-cylinder engine
Item A - alignment bushings
Vehicles with 6-cylinder engine
Item A - alignment bushings
Subframe mount
Vehicles with 4-cylinder engine
Vehicles with 6-cylinder engine
flange shaft M8: 45 Nm
Drive axle to flange shaft M10: 80 Nm
Cover plates above drive axles to transmission: 20 Nm
Clutch slave cylinder to transmission - arrow -: 25 Nm
Shift rod to transmission - arrow A - 20 Nm
Pivot rod to transmission - arrow B 40 Nm
(Fig. here shows manual transmission "012"/"01W".)
Use only bolts and other components listed in Electronic Parts Catalog (ETKA).