Transmission
Transmission
=> [ Removing ]
=> [ Installing ]
Special tools, testers and auxiliary items required
• Slide Hammer-Complete Set (VW 771)
• Engine Support Bridge (10-222 A)
• Bracket with Spindle and Hook (10-222 A/10)
• Adapter (10-222 A/13)
• Engine/Transmission Jack (V.A.G 1383 A)
• Hose Clamps up to 25 mm Dia. (3094)
• Transmission Support (3282)
• Adjustment Plate (3282/33)
• Support Elements (determine when mounting the adjustment plate to the transmission support)
• Transmission Support Jig (3336) for transporting the transmission
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Grease (G 052 735)
• Grease for clutch disc shaft splines (G 000 100 )
• Allocate the grease for the shift mechanism, refer to the parts catalog.
• M10 x 20 Bolt
Removing
- First, check whether a coded radio is installed. If so, obtain the anti-theft code.
- Disconnect the battery Ground (GND) cable with the ignition turned off.
Later in the procedure, the (10-222 A) is connected to the engine lifting eyes.
- Remove the engine cover if it is blocking the lifting eyes.
- Remove the entire air filter housing, if it is located near the battery.
- Remove the battery, the battery cover and tray.
- Remove the shift cable lock washer - 3 - from the transmission shift lever - 1 - and remove the cable from the pin - arrow -.
Metal Relay Lever
- Remove the selector cable retaining washer - 4 - from the relay lever - 2 - and remove the cable from the pin - arrow -.
Plastic Relay Lever
Disconnecting the cable retainer from the selector cable.
• To avoid damage to the selector cable, the cable retainer must be disconnected from the selector lever before removal.
- Pull the securing mechanism forward as far as the stop in the direction of - arrow 1 - and then unlock to the left in the direction of - arrow 2 -.
- Then press the relay lever forward (- direction of arrow 3 -).
- The plastic relay lever is removed together with the cable retainer later in the procedure.
Continuation for All
- Remove the cable mounting bracket bolts and bracket from transmission - arrows -, move it aside and tie it up.
- Clamp off the supply hose to the master cylinder using the (3094).
- Clamp off the hose/line assembly or plastic line - A - to the slave cylinder using the (3094).
- Disengage the clip - arrow - for the hose/line assembly or plastic line as far as the stop.
- Remove the hose/line assembly or plastic line from the breather/slave cylinder and seal it off.
CAUTION!
The clutch pedal must no longer be operated.
- Remove the ground cable - 1 - from the top starter bolt.
- Disconnect the electrical harness connector - 2 - for the backup lamp switch (F4).
- Disconnect the connector and wire from the starter.
- Remove the upper engine/transmission bolts - arrows -.
- Remove the upper bolt for the starter.
- Remove the left and right foam pieces from the upper edge of the fender. Refer to
- Disconnect any hoses and cables in the area of the lifting eyes on the engine.
- Install the (10-222 A) using the (10-222 A/13) in front of the engine hood support.
- Slightly tension the engine/transmission assembly using the spindle.
• Check if an intermediate shaft - arrow - is installed between the right drive axle - A - and the transmission.
• On vehicles with a intermediate shaft, loosen the bolt - 2 - for the right drives axle - 1 - a maximum of 90° with the vehicle resting on its wheels, otherwise the wheel bearing will be damaged.
- Loosen the left and right front drive axle bolts.
- Raise the vehicle.
- Remove the front wheels.
- Remove the noise insulation.
- Remove the lower part of the left front wheel housing liner..
- Remove the front level control system sensor (G78), if equipped.
- Remove the bracket from the starter.
- Remove the starter.
- Disconnect the charge air hose connections - arrows 1 and 2 -.
- Remove the exhaust system suspended mount bolts - arrows - from the subframe.
- Disconnect the exhaust system at the double clamp - arrows -.
- Tie up the front exhaust pipe.
- If installed, remove the support - 1 - for the exhaust system from the transmission - arrow - and front exhaust pipe.
- Remove the pendulum support bolt from the transmission.
- Remove the left drive axle from the transmission flange shaft.
- Secure the drive axles using wire, do not damage the protective coating when doing this.
If an intermediate shaft - C - is installed, remove the right drive axle - A -. Then remove the intermediate shaft from the mounting bracket - D - - arrows - and pull it off from the stub shaft of the transmission.
If an intermediate shaft is not equipped, remove the right drive axle from the transmission flange shaft - A -.
- Remove the drive axle shield bolts - 1 - from the engine.
- Secure the drive axle with wire.
- Remove left and right coupling rods from the stabilizer bar.
- Remove the left and right ball joint to control arm nuts - arrows -.
- Before removing the subframe, locate its position, refer to.
- Remove the subframe with the pendulum supports, stabilizer bar, brackets and control arms.
- Remove the transmission mount bracket bolts - arrows -
- Lower the transmission approximately 60 mm - a - using the spindle.
• When shifting the engine/transmission assembly, pay attention to the coolant hose between the engine and heater core, do not overstretch.
- Remove the transmission mount bracket bolts - arrows -.
Metal Relay Lever
- Pull off locking washer - arrow - from the actuator lever - 1 - and remove the actuator lever.
Plastic Relay Lever
- Remove the relay lever with the cable retainer. Refer to => [ Plastic Relay Lever ] Description and Operation.
Continuation for All
- Remove the transmission shift lever from the shift rod.
- Remove the engine/transmission bolt - arrow -.
- Remove the small cover plate - A - for the flywheel.
- Remove the lower engine/transmission bolts - 2 -.
• Loosen the engine/transmission bolt - 3 - and install it hand tight.
Install the (3282/33) onto the (3282) to remove the transmission.
- Install the (3282) on the (V.A.G 1383 A).
- Align the arms of (3282) according to holes in (3282/33).
- Install the support elements - A - onto the (3282/33) as shown.
- Install the (3282/29) in place of attachment - C -.
- Place the (V.A.G 1383 A) under the vehicle, with the arrow symbol - B - on the (3282/33) pointing to the front of the vehicle.
- Align the (3282/33) parallel to the transmission.
- Secure the (VW 771/40) in the threaded hole of the transmission housing as shown in the illustration.
- Then install the (3282/29) into the hole for the pendulum support bolt on the transmission.
- Secure the transmission to the (3282) using bolt (MD) - A -.
When doing this, the drift - B - should stop at bottom flush with the guide of the (3282) - arrow -.
- Remove the last engine/transmission bolt - C -.
- Separate the transmission from the engine (centering sleeves).
- Rotate the transmission upward near the differential by adjusting the spindle on the (3282).
- Tilt the transmission to the left by adjusting the spindle on the (3282).
- Carefully lower the transmission.
• Pay close attention to the steering gear when lowering the transmission.
• Pay attention to all lines when lowering the transmission.
Installing
• Refer to the "Removing" procedure for the required special tools. Refer to => [ Removing ].
• Replace the self locking nuts and bolts.
• Replace all bolts that have been tightened to a torque angle.
• All cable ties that are opened or cut off during the removal must be replaced in the same positions during installation.
• Clean the input shaft splines - 1 - 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 the clutch plate back and forth on the input shaft until the hub moves freely on the shaft. Excess grease must be removed.
With a Stub Shaft
- Replace the O-ring - arrow - on the stub shaft - 2 - and grease the stub shaft splines with grease (G 000 100).
Continuation for All
- If the transmission is replaced, transfer the transmission shift lever and relay lever.
- All threaded holes in which the self locking bolts are threaded must be carefully cleaned of any remaining locking fluid using a tap.
- Make sure the centering sleeves for the engine to the transmission are installed in the cylinder block, install if necessary.
If the centering sleeves are not installed, difficulty in shifting, clutch problems and possibly noises from the transmission (loose gear chatter) may develop.
- Make sure that the intermediate plate is engaged on the sealing flange and has been installed onto the centering sleeves - arrows -.
- Check the release bearing for wear. Replace the slave cylinder with release bearing, if necessary. Refer to => [ Slave Cylinder with Release Bearing ] Slave Cylinder with Release Bearing.
Ensue the (3282) is equipped with the (3282/33) to install the transmission.
- Align the arms of the (3282) according to holes in the (3282/33).
- Install the support elements - A - onto the (3282/33) as shown.
- Install the (3282/29) in place of the attachment - C -.
- Install the transmission to the (V.A.G 1383 A).
- Align the (3282/33) and transmission parallel to one another.
- Install the (3282/29) into hole for pendulum support bolt to the transmission.
- Secure the (VW 771/40) in the threaded hole of the transmission housing as shown in the illustration.
- Secure the transmission to the (3282) using bolt (MD) - A -.
When doing this, drift - B - should stop at the bottom flush with the guide of the (3282) - arrow -.
- Install the (V.A.G 1383 A) under the vehicle, with the arrow symbol on the (3282/33) pointing to the front of the vehicle.
- Using the spindle on the (3282), adjust the transmission so that the differential area is rotated upward.
- Carefully lift the transmission. Pay close attention to the steering gear.
• Pay attention to all lines when installing transmission.
- Rotate the transmission into the installed position via the spindle on the (3282).
- Align the transmission to the engine and install.
- Install the engine/transmission bolt - C - and tighten to specification.
- Install the lower engine/transmission bolts and tighten to specifications.
- After the transmission is bolted to the engine at the bottom, remove the (3282) from the transmission.
- Install the upper engine/transmission bolts and tighten to specification.
- Install the transmission selector lever to the selector shaft of the transmission, refer to => [ Transmission Shift Lever,
Installing ] Shift Mechanism Overview and tighten the nut - item 17 -=> [ Self Locking Nut ] Shift Mechanism Overview to specification.
Metal Relay Lever
- Install the actuator lever - 1 - into the shift mechanism and clip in the locking washer - arrow -.
Plastic Relay Lever
- Install the relay lever with the cable retainer. Refer to => [ Plastic Relay Lever ] Description and Operation.
Continuation for All
- Install the transmission mount bracket - 1 - to the transmission with new bolts - arrows - and tighten to specifications.
- Align the engine/transmission in the installed position. To do so, raise far enough until the transmission mount bracket - 1 - makes contact with the transmission mount - 2 - completely.
- Install new bolts - arrows - for the engine mount - 2 - to engine mount bracket - 1 - and tighten to specification.
CAUTION!
Only remove the (10-222 A) when all the subframe bolts are tightened to the specification.
- Install the engine/transmission bolt - arrow - and tighten to specification.
- Install the small cover plate - A - for the flywheel.
Transmission with right flange shaft - A -
- Install the right drive axle directly to the transmission flange shaft.
- Install the drive axle heat shield and bolts - arrows -, if equipped.
Transmission with stub shaft - arrow -
On transmissions with a stub shaft, an intermediate shaft - C - must be installed.
- Guide the intermediate shaft - C - through the mounting bracket - D - and onto the transmission stub shaft.
- Tighten the intermediate shaft to the mounting bracket bolts - arrows - to specification.
- Install the right drive axle - A -.
Continuation for All
- Install the subframe/control arm and pendulum support.
• The holes for the pendulum support on transmissions from 28 May 2007 have threaded inserts (for example "Heli-Coil").
• To recognize this look at the collar on the first thread - arrow -.
• Note the correct bolts and tightening specifications.
- Install the pendulum support to the transmission.
- Attach the left drive axle to the transmission flange shaft.
- If applicable, install the front level control system sensor.
- Assemble the exhaust system and attach the exhaust system suspended mount to the subframe.
- If equipped, install the exhaust system support - 1 - and fasten it to the transmission - arrow -.
- Install the charge air hose.
- Install the starter and fasten it with the lower bolt.
- Secure the bracket for the wires at the lower starter bolt.
- Install the upper starter bolt and attach the connector and wiring to the starter.
- Secure the ground (GND) cable - 1 - to the upper starter bolt.
- Connect the connector - 2 - to the backup lamp switch.
- Push the hose/line assembly or plastic line - A - into the breather/slave cylinder up to the stop and push the clip - arrow - downward.
- Pull on the line to check the installation.
- Remove the (3094) from the hose/line assembly and supply hose.
- After removing the (3094), bring the supply hose back to its original shape.
- Bleed the clutch system. Refer to => [ Clutch System, Bleeding ] Procedures.
- Install the cable mounting bracket to the transmission and tighten the bolts - arrows - - item 6 -=> [ Bolt ] Shift Mechanism Overview or nuts - item 10 -=> [ Nuts ] Shift Mechanism Overview to specification.
- Apply a small amount of grease to the pin - arrow - on the transmission shift lever - 1 -.
Allocate the grease, refer to the parts catalog.
- Replace the lock washer - 3 - after every disassembly.
Metal Relay Lever
- Apply a small amount of grease to the pin - arrow - on the relay lever - 2 -.
Allocate the grease, refer to the parts catalog.
- Slide the selector cable onto the pin - arrow - and secure with the retaining washer - 4 -.
Plastic Relay Lever
- Insert the selector cable in the cable retainer.
Continuation for All
- Adjust shift mechanism. Refer to => [ Shift Mechanism, Adjusting ] Adjustments.
- Install the battery tray, cover and battery.
- If removed, install the entire air filter housing.
- Install the foam pieces on the left and right fender upper edges. Refer to
- Install the engine cover if necessary.
- Connect the battery and observe the procedure after connecting battery.
- Check the transmission fluid. Refer to => [ Transmission Fluid, Checking ] Testing and Inspection.
- Install the lower part of the left front wheel housing liner..
- Install the noise insulation.
- Install the wheels.
- Check the headlamp adjustment on vehicles with front level control system sensor.
Tightening Specifications
Transmission to Engine Bolts
- A and B - : alignment bushings for centering.
- Replace the bolts - 1 through 5 -.
Small cover plate for flywheel bolt: 10 Nm.
Transmission Mount Bracket to Transmission Bolt
- Replace the bolts - arrows -.
Tighten the bolts to 60 Nm + 90° (1/4) additional turn.
Transmission Mount to Transmission Mount Bracket Bolt
- Replace the bolts - arrows -.
Tighten the bolts to 60 Nm + 90° (1/4) additional turn.
• Install the engine/transmission mounts free of tension.