Installing Transmission
Installing transmission, 012/01W, 5 SPD. M/T
^ Clean input shaft splines 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.
^ Shifting difficulties, coupling problems or transmission noises (idler gear rattling) may occur, if centering sleeves are not installed.
^ If installed, make sure intermediate plate is seated properly at engine.
^ Coat contact surface of clutch release lever plunger with a thin layer of copper grease.
^ All threaded bores in which self-locking bolts are threaded must be carefully cleaned of remaining locking fluid using a tap.
^ Assembly transmission jack with Transmission Support 3282, Adjustment Plate 3282/10 for "012"/"01A" transmissions, and attachments as follows:
^ Set Adjustment Plate 3282/10 on to Transmission Support 3282 (adjustment plate only fits in one position).
^ Align transmission support arms to correspond with the holes in adjustment plate.
^ Screw in attachments - A -, as depicted on adjustment plate.
^ Place transmission onto transmission jack
^ Align adjustment plate and transmission parallel to each other.
^ Lock safety support - arrow - on transmission.
^ Set transmission jack under the vehicle, arrow - B -, (fig. V 34-2583) 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 -.
^ If present, install Engine Speed (RPM) Sensor G28 on coupling housing - arrow -.
^ If present, place intermediate plate between transmission and engine on to engine centering sleeves.
^ When installing the transmission, make sure that driveshaft flanges engage with transmission flange shafts.
^ Insert transmission.
^ When installing, press engine slightly up at torque support (in - direction of arrow -; second mechanic).
^ Screw in bolts for engine/transmission mount at bottom and for starter; install starter.
Vehicles with 5-cylinder engine
^ Install right transmission support at transmission.
^ Lift up engine via spindle of engine support bridge 10 - 222 A until engine fan contacts lock carrier beneath.
^ Fit the remaining bolts for engine/transmission mount at bottom - arrows A -, - B - and - C -.
^ Bolt left and right transmission support with bonded rubber bushing to subframe.
^ Bolt torque support onto engine.
^ Tighten new nuts on both engine mounts.
Note:
^ Install engine/transmission beating tension-free.
Vehicles with 4-cylinder engine and 6-cylinder engine
^ Bolt left and 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 with 6-cylinder engine).
Note:
^ Install engine/transmission beating free of tension.
Continuation for all vehicles
^ Install drive axles to drive flanges
^ Install cover plate over right drive axle - arrow 1 - and - arrow 2 -.
^ Install cover plate over left drive axle, if installed.
^ Push shift rod on so that securing bolt fits into recess of shift rod.
^ Only then secure shift rod - arrow A -.
^ Secure pivot rod to transmission - arrow B-.
^ Install front exhaust pipe with catalytic converter.
^ Install noise insulation pan on bottom of engine/transmission, if installed.
^ Connect connector for back-up lights - arrow B -.
^ Connect connector for speedometer Vehicle Speed Sensor (VSS) - arrow A -.
^ Install connecting bolts for engine/transmission.
^ Tighten expansion tank for cooling system.
^ Install Mass Air Flow (MAF) to intake air hose.
^ Attach intake air scoop.
^ Assemble intake manifold cover.
^ Connect battery Ground (GND) strap.
Note:
^ For vehicles equipped with coded anti-theft radio, note code.
^ Gear oil, checking.
^ Adjust shift mechanism - shift lever must be pressed down to engage reverse gear.
^ Adjust shift mechanism - shift lever cannot be pressed down to engage reverse gear.
Tightening torques
Transmission to engine
Vehicles with 4-cylinder engine
In conjunction with some engines M12 x 110 or M12 x 130, tightening torque 65 Nm
Item A-bushings
Vehicles with 5-cylinder engine
Item A - bushings
Vehicles with 6-cylinder engine
Item A -bushings
Subframe mount
Vehicles with 4-cylinder engine
Vehicles with 5-cylinder engine
Vehicles with 6-cylinder engine
Flange shaft M6: 45 Nm
Drive axle to flange shaft M10: 70 Nm
Cover plate above drive axles to transmission: 20 Nm
Clutch slave cylinder to transmission - arrow - (use new bolt!): 25 Nm
Shift rod (shift coupling) to transmission - arrow A - (use new bolt!): 23 Nm
Pivot rod to transmission - arrow B -: 40 Nm
Bolts and other components which come into direct contact with the transmission have a surface coating which is adapted to transmission housings made out of aluminum or magnesium
Therefore, only use bolts and other components that are listed in the Electronic Parts Catalog (ETKA).