Transmission

Transmission

=> [ Removing ]

=> [ Installing ]

=> [ Tightening Specifications ]

Special tools, testers and auxiliary items required

• Engine Support Bridge (10-222 A)

• Engine Support Feet (10-222 A/8)

• Adapter (10-222 A/18)

• Adjustment Plate (3282/39)

• Support Elements (determine when mounting the adjustment plate on the transmission support)

• Transmission Support (3282)

• Plate (T10419)

• Shackle (10-222 A/12)

• Engine-/Gearbox Jack (V.A.G 1383 A)

• Support (T10036 A) or (T10036)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Engine Support Device (3300 A)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Transmission Support Jig (3336)

• Grease for Clutch Plate Splines (G 000 100)

• M6 x 20 Hex Socket Head Bolt (Qty: 2)

• M6 x 80 Bolt

- If using the support (T10036) , drill two 7 mm holes as illustrated.






• - a - = 11 mm

• Dimension - b - = 98 mm

• Dimension - c - = 70 mm

The engine support bridge (10-222 A) and the engine support feet (10-222 A/8) will be mounted on the longitudinal members later in the procedure.






• To protect the edges of the fenders, cover both engine support feet (10-222 A/8) with cloth tape - arrow -. Refer to the Parts Catalog.

Removing

- First, check whether a coded radio is installed. If so, obtain the anti-theft code.

- Turn off the ignition and disconnect the battery ground cable.

- Remove the engine cover with air filter.

- Remove the batter and the battery tray.

- Remove the cable retainer from the selector cable. Refer to => [ Plastic Relay Lever ] Plastic Relay Lever.

- Remove the clip - arrow 1 - and the relay lever together with the cable retainer.

- Remove the shift cable lock washer - arrow 2 - from the selector lever - A -.

- Remove the shift cable from the pin.






- Remove the nut - arrow 3 - and then remove the transmission shift lever - A -.

- Remove the cable bracket bolts - arrows - and bracket from the transmission.






- Tie up the shift and selector cables.

- Remove the bracket - B - from the transmission and then pull it off the hose/line assembly - A -.

- Remove the transmission support bolts - arrows A - and support.






- Remove the slave cylinder bolts - arrow B - and slave cylinder and lay it aside, secure with wire, do not open the hydraulic system.


Do not press the clutch pedal anymore.

- Disconnect the connector - arrow 1 - from the backup lamp switch (F4).






- Disconnect the connector - arrow 2 - and wire - arrow 3 - from the starter.

- Disconnect the ground cable from the upper engine/transmission bolt.

- Remove the upper bolt from the starter.

- Remove the upper engine/transmission bolts.

- Remove the vacuum hose to prevent damaging it - arrow -.






• The engine support bridge (10-222 A) will be attached to the engine and will be used to lower the engine/transmission later in the procedure.






• Some engines have a secondary air injection solenoid valve (N112) - arrow - on the back.

• Both upper threaded holes for the secondary air injection solenoid valve bolts are needed to attach the engine to the engine support bridge (10-222 A) (see - arrow - in the lower illustration).

• For this reason it is necessary to remove the secondary air injection solenoid valve.

- Attach the plate (T10419) to the back of the engine in the - direction of the arrow -.






- Tighten the plate bolts to the threaded holes - arrows -.






Tightening specification: 10 Nm


Always tighten the bolts to specification.

The lifting eye - arrow A - at the front of the engine is also used to hold the engine.






- Release the transport strap - arrow B - and remove it from the lifting eye - arrow A -. Do not disconnect the wire connections.

- Install the engine support bridge (10-222 A) in front of the engine hood support.






- Use the following special tools:

• Engine support feet (10-222 A /8)

• Adapter (10-222 A/18)

- Position the engine support feet (10-222 A/8) :

• On the upper longitudinal members, directly in front of the ridge (- arrow 1 -) next to the bolt (- arrow 2 -)

- Attach the shackle (10-222 A/12) to the front of the engine on the left side.

- Connect the plate (T10419) and the shackle (10-222 A/12) using the engine support bridge.

- Tension the engine/transmission assembly slightly using the spindles.

- Lift the vehicle.

- Remove the noise insulation.

- Remove the lower part of the left front wheel housing liner..

- Disconnect all wires from the transmission.

- Remove the starter.






- Remove the left front level control system sensor (G78) from the control arm, if equipped.

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






- Remove the drive axles from the flange shafts and tie them up as high as possible. Be careful not to damage the surface protection.

- Remove the 4 nuts - 2 - and suspended mount bolts - 3 - and remove the front exhaust pipe - 1 - from the exhaust manifold.






- Remove the pendulum support.






- Remove the transmission mount to transmission mount bracket bolts - arrows -.






- Bring the engine/transmission assembly into an angled position by lowering it using the engine support bridge (10-222 A) spindles.

• The bolts - arrows - for the transmission mount bracket - A - must be accessible.

- Remove the transmission bracket - A - to transmission bolts - arrows -.






- Remove the heat shield bolts - arrows - and shield from the subframe, if equipped.






- Install the support (T10036) or the (T10036 A) to the subframe using two M6 x 20 socket head bolts - arrows -.






- Install the engine support device (3300 A) to the support - A -.






- Push the engine forward using the spindle on the engine support device (3300 A). Note the following when doing this:






• The Air Conditioning (A/C) compressor - 2 - must not touch the refrigerant line - 1 - - arrow -.

• The generator must not touch the refrigerant line.

• The pressure pipe must not touch the radiator.

To remove the transmission, the adjustment plate (3282/39) must be installed on the transmission support (3282).

- Install the transmission support (3282) onto the engine-/gearbox jack (V.A.G 1383A).

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

- Install the mounting elements - A and C -, on the adjustment plate, as illustrated.






- Position the engine-/gearbox jack under the vehicle. The arrow symbol - B - on the adjustment plate points in the direction of travel.

- Align the adjustment plate so that it is parallel to the transmission and secure the safety support to the transmission.






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

- Remove the lower engine/transmission bolts.

- Remove the transmission from the alignment sleeves and carefully move it toward the subframe.






- Guide the right flange shaft past the hole - arrow 1 -.






- Carefully lower the transmission.

- Guide the right flange shaft past the flywheel - arrow 2 - (see the upper illustration).

- Guide the left flange shaft - B - past the subframe - arrow - as illustrated.






- Use the spindles on the transmission support (3282) to adjust the position of the transmission while lowering it.

• Pay attention to the lines when lowering the transmission.

Installing

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

Pay attention to the following list for the subject -"Transmission Fluid, Checking and Filling"






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

- Always replace self-locking nuts and bolts.

- Make sure the alignment sleeves for centering the engine/transmission are installed inside the cylinder block. Install them 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 fits correctly on the engine.

- Clean the splines on the input shaft and then lubricate them lightly with grease for clutch plate splines (G 000 100).

It must be possible to slide the clutch disc back and forth on the input shaft.

- Remove the heat shield bolts - arrows - and shield from the subframe , if equipped.






- Install the support (T10036) or (T10036 A) to the subframe using two M6 x 20 socket head bolts - arrows -.






- Install the engine support device (3300 A) to the support - A -.






- Push the engine forward using the spindle on the engine support device (3300 A). Note the following when doing this:






• The Air Conditioning (A/C) compressor - 2 - must not touch the refrigerant line - 1 - - arrow -.

• The generator must not touch the refrigerant line.

• The pressure pipe must not touch the radiator.

To install the transmission, the adjustment plate (3282/39) 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 mounting elements - A and C - ( pin (3282/29) ) on the adjustment plate as illustrated.






- Place the transmission on the engine-/gearbox jack.

- 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.






- Position the engine-/transmission jack under the vehicle. The - arrow symbol B - on the adjustment plate points in the direction of travel.

- Carefully lift the transmission.

- Guide the right flange shaft past the flywheel - arrow 2 -.






- Guide the left flange shaft - B - past the subframe - arrow - as illustrated.






- Guide the right flange shaft past the hole - arrow 1 - (see the previous illustration)

- Raise the transmission up to the engine.

- Align the transmission with the engine and install it.

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

- After the transmission is attached to the engine, remove the engine-/gearbox jack from the transmission.

- Remove the engine support device (3300 A) and the support.

- Install the heat shield and bolts - arrows - to the subframe, if it was removed earlier.






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

- Attach the transmission mount bracket - A - with new bolts- arrows -, to the transmission and tighten them to specification. Refer to => [ Tightening Specifications ].






- Use bolt spindles on the engine support bridge (10-222 A) to align the engine/transmission in its installed position.






- Install new transmission mount to transmission mount bracket bolts - arrows - and tighten to specification. Refer to => [ Tightening Specifications ].


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

• Install the engine/transmission mount free of tension.

- Install the drive axles.

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






- Install the pendulum support.






- Install the exhaust system and then secure the suspended mount to the subframe.

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






- Install the vacuum hose - arrow -.






- Install the slave cylinder and tighten the bolts - B arrows - to specification, see - item 9 - in => [ Clutch Release Mechanism Overview ] Description and Operation.






- Install the transmission support and bolts - arrows A - and tighten them to specification. Refer to => [ Tightening Specifications ].

- Connect the connector - 1 - to the backup lamp switch (F4).






- Install the starter, connect the connector - arrow 2 - and attach the wire - arrow 3 -.

- Attach the ground cable to the upper engine/transmission bolt.

- Attach the bracket - B - to the transmission.






- Press the hose/line assembly - A - into the bracket - B - on the transmission.

- Install the cable bracket to the transmission and tighten the bolts - arrows - to specification, see - item 6 - in => [ Shift and Selector Cables, with a Metal Cable Bracket and Relay Lever ] Shift Mechanism Overviews or - item 13 - in => [ Shift and Selector Cables, with a Plastic Cable Bracket and Relay Lever ] Shift Mechanism Overviews.

- Install the transmission shift lever - A -. Refer to => [ Transmission Shift Lever, Installing ] Shift Mechanism Overviews.






- Tighten the nut - arrow 3 - to specification, see - item 18 - in => [ Shift and Selector Cables, with a Metal Cable Bracket and Relay Lever ] Shift Mechanism Overviews.

- Apply a small amount of grease to the transmission shift lever pin - A -.

For the correct grease, refer to the Parts Catalog.

- Attach the shift cable to the transmission shift lever.

- Replace the lock washer - arrow 2 - after every disassembly.

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

• The clip - arrow 1 - secures the relay lever.

• Make sure the clips locks securely.

- Install the selector cable any the cable retainer.

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

- Remove the shackle (10-222 A/12) from the engine.

- Attach the transport strap to the lifting eye on the engine - arrow A - and tighten it - arrow B -.






- Remove the strap (T10419) from the back of the engine.






- Install the secondary air injection solenoid valve (N112) - arrow -, if was removed earlier.






- Install the battery tray, the battery and cover.

- Install the engine cover with air filter.

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

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

- Install the noise insulation.

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

Tightening Specifications

Transmission to Engine Bolt Tightening Specifications











- A - alignment sleeves for centering

Transmission Mount Bracket to Transmission






- Replace the bolts- arrows -.

- Tighten all the bolts hand tight.

- Tighten the bolt to 40 Nm + 90° (1/4) additional turn.

Transmission Mount to Transmission Mount Bracket






- Replace the bolts - arrows -.

- Tighten all the bolts hand tight.

- Tighten the bolt to 60 Nm + 90° (1/4) additional turn.

Transmission Support to Transmission Mount Bracket and Transmission






- Replace the bolts- arrows -.

- Tighten all the bolts hand tight.

- Tighten the bolt to 20 Nm + 90° (1/4) additional turn.