Transmission, Installing
Transmission, Installing
• Refer to work procedure "removing transmission" => [ Transmission, Removing ] Transmission, Removing, for special tools required.
Observe the Following Assembly for "Checking and Filling up Gear Oil"
- All threaded bores in which self-locking bolts are threaded must be carefully cleaned of remaining locking fluid using a tap.
- Always replace self-locking nuts and bolts.
- Always replace bolts that are secured with tightening specification, as well as seals, gaskets and O-rings.
- All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
- Make sure alignment sleeves for centering engine/transmission are installed in cylinder block; install if necessary.
If centering sleeves are not present, problems with shifting, changing gears and possibly a noisy transmission (idler rattling) may occur.
- Make sure intermediate plate is correctly seated on engine.
- Clean serrated splines of input shaft and (in case of used clutch plate) clean hub splines, remove corrosion and apply only a very thin coating of lubricant for clutch plate splines (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.
- Bolt in support channels (VW 457/1) in threaded holes for attachment bolts/pendulum support to subframe.
- Spacer discs with a total thickness of 6 mm must be inserted between subframe and support channel (VW 457/1).
A M8 x 25 hex bolts (2x)
• Instead of support channels (VW 457/1), the support (T10036) can also be used.
- Install engine support device (3300 A ) and tighten - arrows -.
- Carefully push engine toward front.
• While shifting engine, pay attention to all lines.
Transmission support (3282) is equipped with adjustment plate ( 3282/39) to install transmission " 0A4".
- Align transmission support arms to correspond with holes in adjustment plate.
- Bolt in attachments - A - and - C - (pin (3282/29)), as depicted on adjustment plate.
Arrow symbol - B - on adjustment plate points in direction of travel.
- Attach transmission to engine/transmission jack ( V.A.G 1383 A).
- Align adjustment plate and transmission parallel to each other.
- Bolt in pin (3282/29) in bore for mounting bolt of pendulum support to transmission.
- Place engine/transmission jack under vehicle.
- Carefully raise transmission, guide with right drive flange - A - in area of flywheel and with left drive flange - B - in area of subframe, as shown.
- Change position of transmission when raising via spindles of transmission support (3282).
• Pay attention to all wires when raising transmission.
- Align transmission in installation position properly to engine and insert.
- Bolt in bolts for engine/transmission mount at bottom and tighten to specification.
- After transmission is bolted to engine, remove engine/transmission from transmission.
- Remove engine support device (3300 A) - arrows -.
- Remove bolts - A - and remove support channels (VW 457/1).
- Bolt in bolts for engine/transmission mount at top and tighten to specification.
- Install console - A - on transmission with new hex bolts - arrows - and tighten to specification.
- Align engine and transmission to installation position via both spindles of engine support bridge (10 - 222 A).
- Install new bolts - arrows - of left transmission mount into transmission mount and tighten to specification.
CAUTION!
Only remove engine support bridge (10 - 222 A) when bolts for subframe mount are tightened to specifications.
• Install engine/transmission mount free of tension.
- Install end plate plenum chamber.
- Install fan and, if present, auxiliary fan.
- Install in bolt - arrow A - for engine/transmission mount and tighten to specification.
- Install pendulum support and tighten with new bolts - arrows -.
- Install front exhaust pipe bracket to subframe - arrows -.
- Assemble exhaust system and align free of stress.
- Install small cover plate for flywheel behind right drive flange - A - - arrows -.
- Install drive axles on transmission.
- If present, install protective cap for drive axle to engine, tighten bolts - arrows - to specification.
- Install starter.
- Install slave cylinder and tighten bolts - arrows B - to specification => [ (Item 13) Hex bolt, 20 Nm ] Removal and Replacement.
- Install transmission support - arrows A - and tighten to specification.
- Connect connector - arrow 1 - for backup lights.
- Connect connector - arrow 2 - to starter.
- Connect wire - arrow 3 - to starter.
- Install ground (GND) cable to connecting bolt at top of engine/transmission.
- Install bracket - B - on transmission, tighten bolt to specification => [ (Item 18) Hex bolt, 20 Nm ] Removal and Replacement.
- Press hose/line assembly - A - into bracket - B - on transmission.
- Install cable mounting bracket on transmission and tighten bolts - arrows - to specification => [ (Item 6) Hex bolt, 20 Nm ] Service and Repair.
- Install transmission shift lever - A -.
- Tighten hex nut - arrow 4 - to specification => [ (Item 18) Self-locking hex nut, 23 Nm ] Service and Repair.
- Insert relay lever - B - and secure with locking washer - arrow 3 -.
- Apply a small quantity of grease (G 000 450 02 ) on pin of transmission shift lever - A - and relay lever - B -.
- Connect shift cable with transmission shift lever and selector cable with relay lever.
- Secure cable retainer using new lock washers - arrow 1 - and - arrow 2 -
- Adjust shift mechanism => [ Shift Mechanism, Adjusting ] Adjustments.
- Install battery tray and battery.
- If power steering refill tank is located at battery tray, secure it to battery tray, do not kink hoses.
- Install complete air filter housing.
- Install engine cover.
- Connect battery and observe work steps after connecting battery.
- Install center, left and right sections of noise insulation beneath engine/transmission
Tightening Specifications
Transmission to engine
Item no. - A - centering sleeves
Transmission bracket - A - to transmission
- Hand-tighten all bolts.
- Tighten bolts to specification.
Transmission mount to chassis
- Hand-tighten all bolts.
- Tighten bolts to specification.
• Install engine/transmission mount free of tension .
Transmission support to transmission bracket and transmission
- Hand-tighten all bolts.
- Tighten bolts to specification.
