Transmission, Installing

Transmission, Installing

• Refer to "Transmission, Removing" to get a list of the special tools needed. Refer to => [ Transmission, Removing ] Transmission, Removing.

• Replace the self-locking nuts and bolts.

• Replace bolts that were tightened to an additional torque angle.

• Install any cable ties that were loosened or cut off during removal in their same location.

• Clean the input shaft splines and (on a used clutch disc) the hub splines. Remove any corrosion and then apply a very thin coat of grease for clutch disc splines (G 000 100) on the splines. Then move the clutch disc back and forth on the input shaft until the hub moves freely on the shaft. The excess grease must be removed.

- If the transmission is replaced, transfer the transmission shift lever and the relay lever.

- Clean all threaded holes for self-locking bolts with a thread tap to remove any locking fluid residue.

- Check whether there are alignment sleeves for the engine/transmission in the cylinder block; install if necessary.

If the alignment sleeves are missing, it will be difficult to shift, there will be clutch problems and the transmission may make noises (loose rattling).

- Make sure the intermediate plate is engaged on the sealing flange and pushed onto the alignment sleeves - arrows -.






- Check the release bearing for wear. If necessary, replace the slave cylinder and the release bearing. Refer to => [ Slave Cylinder with Release Bearing ] Slave Cylinder with Release Bearing.

To install the transmission the adjustment plate (3282/33) must be installed on the transmission support (3282).






- Align the arms of the transmission support so that they match up with the holes in the adjustment plate.

- Install the support elements - A - as illustrated on the adjustment plate.

- Install the pins (3282/29) in place on the adjustment plate - C -.

- Place the transmission on the engine-/gearbox jack (V.A.G 1383 A).

- Align the adjustment plate so that it is parallel to the transmission.

- Install the pin (3282/29) into the hole on the transmission for the pendulum support bolt.

- Install the adapter (VW 771/40) in the threaded hole in the transmission housing as illustrated.






- Secure the transmission to the transmission support (3282) using a M6 x 80 bolt - A -.

The arm - B - must be flush with the guide on the transmission support (3282) - arrow -.

- Place the engine-/gearbox jack (V.A.G 1383 A) under the vehicle. The arrow points in the direction of travel.

- Using the spindles on the transmission support (3282) , adjust the transmission so that the differential area is rotated upward.

- Lift the transmission. Be careful of the steering gear - 3 -.






• Pay attention to the lines when installing the transmission.

The right flange shaft - 1 - must be guided over the bolt flange on the cylinder block - 2 -.

- Turn the transmission into its installed position using the spindles on the transmission support (3282).

- Line up the transmission and the engine and install it.

- Install the engine/transmission bolt - C - and tighten it to specification. Refer to => [ Transmission to Engine Tightening Specifications ] Mechanical Specifications.






- Install the engine/transmission bolt - arrow - and tighten it to specification. Refer to => [ Transmission to Engine Tightening Specifications ] Mechanical Specifications.






- Install the lower engine/transmission bolts and tighten them to specification. Refer to => [ Transmission to Engine Tightening Specifications ] Mechanical Specifications.

- Remove the transmission support (3282) after the transmission is bolted to the engine at the bottom.

- Install the upper engine/transmission bolts and tighten them to specification. Refer to => [ Transmission to Engine Tightening Specifications ] Mechanical Specifications.

- Install the transmission shift lever to the gear shift unit, refer to => [ Transmission Shift Lever, Installing ] Shift Mechanism Overviews and tighten the nut => [ (Item 17) Nut, Self Locking ] Shift Mechanism Overviews to specification.

With a Metal Relay Lever:






- Install the relay lever - 1 - in the gear shift unit and install the lock washer - arrow -.

With a Plastic Relay Lever:

- Install the relay lever with the cable retainer. Refer to => [ Plastic Relay Lever ] Plastic Relay Lever.

Continuation for all:

- Install the transmission mount bracket - 1 - with new bolts - arrows - to the transmission and tighten the bolts to specification. Refer to => [ Transmission to Engine Tightening Specifications ] Mechanical Specifications.






- Align the engine/transmission in its installed position. Lift it until the transmission mount bracket - 1 - is in complete contact with the transmission mount - 2 -.






- Install the new transmission mount bolts - arrows - to the transmission mount bracket - 2 - and tighten them to specification. Refer to => [ Transmission to Engine Tightening Specifications ] Mechanical Specifications.


Only remove the engine support bridge (10-222 A) when all the transmission mount bolts are tightened to specification.

- Install the small cover plate - A - for the flywheel behind the right flange shaft. Refer to => [ Transmission to Engine Tightening Specifications ] Mechanical Specifications.






- Attach the coolant pipes - B - to the engine - arrows - if they were removed earlier.

- Install the subframe with the control arms and pendulum support.

• The holes for the pendulum support in transmissions from 28 May 2007 have threaded inserts (for example a "Heli-Coil").

• How to recognize: The shoulder at the first thread - arrow -.






• Be sure to use the correct bolts and tightening specification.

- Install the pendulum support to the transmission.






- Install the drive axles to the transmission.






- Install the drive axle heat shield and bolts - arrows -, if equipped.

- Install the left front level control system sensor (G78) , if equipped.






- Connect the connector to the oil level thermal sensor (G266).

- Assemble the exhaust system and then secure it to the subframe.

- Attach the exhaust system support - 1 -, if equipped, to the transmission - arrow - and to the front exhaust pipe.






- Install the charge air hose.

- Install the starter and tighten the lower bolt.

- Attach the bracket for the lines to the lower starter bolt.

- Install the top bolt on the starter and attach the connectors and the cables to the starter.

- Attach the ground strap - 1 - to the top starter bolt.






- Connect the connector - 2 - to the backup lamp switch (F4).

- Push the hose/line assembly or pipe - A - into the breather assembly/slave cylinder to the stop and push the clip - arrow - downward.






- Pull on the line to make sure it is secure.

- Remove the hose clamp up to 25 mm dia. (3094) from the hose/line assembly or supply hose.

- After removing the hose clamp up to 25 mm dia. (3094) , bring the return hose back to its original shape.

- Bleed the clutch system. Refer to => [ Clutch System, Bleeding ] Procedures.

- Make sure the vacuum hose for the brake system is installed correctly.

- Install the cable bracket to the transmission and tighten the bolts/nuts - arrows - to specification, see => [ (Item 6) Bolt ] Shift Mechanism Overviews and => [ (Item 10) Nut ] Shift Mechanism Overviews.






- Apply a small amount of grease (G 000 450 02) to the pin - arrow - on the transmission shift lever - 1 -.






- Replace the lock washer - 3 - after every disassembly.

With a Metal Relay Lever:

- Apply a small amount of grease (G 000 450 02) to the pin - arrow - on the relay lever - 2 -.

- Slide the selector cable onto the pin - arrow - and secure with the lock washer - 4 -.

With a Plastic Relay Lever:

- Insert the selector cable into the cable retainer.

Continuation for all:

- Adjust the shift mechanism. Refer to => [ Shift Mechanism, Adjusting ] Adjustments.

- Install the battery tray and the battery.

- If removed, install the entire air filter housing.

- Install the engine cover, if necessary.

- Connect the battery and then complete the steps after connecting the battery.

- Check the transmission fluid level. Refer to => [ Transmission Fluid, Checking ] Service and Repair.

- Install the lower section of the left front wheel housing liner.

- Install the noise insulation.

- Install the wheels.

- Check the headlamp adjustment if the vehicle has a left front level control system sensor.