Transmission, Installing
Transmission, Installing
• Refer to the work procedure "Transmission, Removing" --> [ Transmission, Removing ] Transmission, Removing, for the special tools required.
• All threaded bores in which self-locking bolts are threaded must be carefully cleaned of locking fluid using a thread tap.
• Always replace self-locking nuts and bolts.
• Always replace bolts that are secured with tightening specifications as well as sealing rings, gaskets and O-rings.
• All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
- Make sure centering sleeves for engine to transmission are installed in cylinder block, install if necessary.
If alignment sleeves are not installed, difficulty in shifting, clutch problems and possibly noises from transmission (loose gear chatter) may develop.
- Make sure that the intermediate plate is hooked into sealing flange and is pushed onto alignment sleeves - arrows -.
- Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of lubricant (G 000 100) on splines. Then move clutch plate on input shaft back and forth until hub on shaft moves easily. Always remove excessive applied grease.
- Check release bearing for wear. If necessary, replace slave cylinder with release bearing --> [ Clutch Release Mechanism Assembly Overview ] Clutch Release Mechanism Assembly Overview.
Transmission support (3282) is equipped with adjustment plate (3282/33) to install transmission.
- Align transmission support arms to correspond with holes in adjustment plate.
- Screw in attachments - A -, as depicted on adjustment plate.
- Screw in pin (3282/29) in place of attachment - C -
- Attach transmission to engine/transmission jack (V.A.G 1383 A).
- Align adjustment plate and transmission parallel to each other.
- Screw stud (3282/29) into hole for mounting bolt of pendulum support on transmission.
- Secure adapter (VW 771/40) in threaded hole of transmission housing as shown in the illustration.
- Secure transmission on transmission support (3282) using bolt (M10 x 20) - A -.
When doing this, the drift - B - should sit flush at bottom with guide of transmission support (3282) - arrow -.
- Place engine/transmission jack (V.A.G 1383 A) under vehicle, arrow on adjustment plate pointing to front of vehicle.
- Using spindles of transmission support (3282) , adjust transmission so that the differential area is rotated upward.
- Carefully lift transmission, pay attention to electromechanical steering gear - 3 -.
• Pay attention to all lines when installing transmission.
Right flange shaft - 1 - must be guided over bolt-on eyelet of engine - 2 -.
- Use spindles of transmission support (3282) to rotate transmission to installation position.
- Align transmission to engine (alignment sleeves) and install.
- Insert engine/transmission connecting bolt - C - and tighten to tightening specifications.
- Screw in engine/transmission connecting bolt - arrow - and tighten to tightening specifications.
- Screw in lower engine/transmission connecting bolts - 4 - and tighten to tightening specifications.
- After transmission is bolted to engine at bottom, remove transmission support (3282) from transmission.
- Install transmission shift lever onto transmission shift rod and tighten hex nut to tightening specifications --> [ (item 17) Self-locking hex nut, 23 Nm ] Shift and Selector Cables.
- Insert relay lever - 1 - into selector mechanism and clip in lock washer - arrow -.
- Install console - 1 - with new hex bolts on to transmission - arrows - and tighten to tightening specifications.
- Align engine/transmission in Installed location. To do this, lift until bracket - 1 - is in complete contact with left engine mount - 2 -.
- Install new bolts - arrows - of left engine mount - 2 - into bracket - 1 - and tighten to tightening specification.
CAUTION!
Do not remove engine support bridge (10 - 222 A) until all bolts for left assembly mounting have been tightened to tightening specification.
• Install engine/transmission bearing free of tension
- Screw in upper engine/transmission connecting bolts - 1 - and tighten to tightening specifications.
- Install small cover plate for flywheel - arrows -.
- Install left and right drive axles onto flange shafts - A - of transmission.
- Install heat shield and bolts- arrows - for drive axle on engine if present, tighten bolts to tightening specification.
- If installed, connect connector to oil level thermal sensor (G266).
- Install subframe with pendulum support, stabilizer bar, brackets and control arms.
- Install steering gear on to subframe
- Install pendulum support on to transmission, to do so, screw in bolts - 2 - and - 3 - and tighten to tightening specifications
- Use new bolts when securing.
- If present, install left front level control system sensor (G78) - arrows -.
- Install bracket for exhaust system on subframe - arrows -26 Description and Operation.
- If present, install support - 1 - for exhaust system and bolt tightly to tightening specification on transmission - arrow - and on front exhaust pipe
- Assemble exhaust system and align free of tension
- Connect connecting hose to charge air pipe - arrow -21 Description and Operation.
- Insert starter and bolt firmly with lower bolt
- Secure bracket for wires at lower starter bolt.
- Install upper starter bolt, connect connector and wires to starter.
- Secure ground (GND) cable - 1 - to upper starter bolt.
- Connect back up lights connector - 2 -.
- Slide hose/line assembly - A - into bleeder/slave cylinder until it stops and press down clip - arrow -.
- Remove hose clamps (3094).
- Install cable mounting bracket on to transmission and tighten bolts or nut - arrows - to tightening specifications--> [ 6 Hex bolt, 20 Nm ] Shift and Selector Cables and --> [ (item 10) Nut, 20 Nm ] Shift and Selector Cables.
- Spread a small quantity of grease (G 000 450 02) on pin - arrows - of transmission shift lever - 1 - and of relay lever - 2 -.
- Replace lock washers - 3 - and - 4 - after every disassembly.
- Slide selector cable and shift cable on to respective pin - arrows - and secure with lock washers - 3 - and - 4 -.
- Bleed clutch system --> [ Clutch System Bleeding ] Clutch System Bleeding.
- Adjust selector mechanism --> [ Selector Mechanism, Adjusting ] Adjustments.
- Install battery console and battery -->.
- Install cover for engine (possibly with integrated air filter)24 Description and Operation.
- Connect battery and follow work procedures after connecting battery.
- Check gear oil --> [ Transmission Oil, Checking ] Transmission Oil, Checking.
- Install wheels
- Install front section of left front wheel housing liner
- Install sound insulation
Tightening Specifications
Transmission to Engine
Item - A - and item - B -: Alignment bushing for centering
Replace bolts - 1 - to - 5 -.
Transmission bracket - 1 - to transmission
Transmission to body
• Install engine/transmission bearing free of tension
