Transmission, Installing
Transmission, Installing
• Refer to "Transmission, Removing" to get a list of the special tools needed. Refer to => [ Transmission, Removing ] Transmission, Removing.
- Clean all threaded holes with a tap to remove any locking fluid residue.
- Always replace the self locking nuts and bolts.
- Make sure the alignment bushings for centering the engine/transmission are installed inside the cylinder block. Install them if necessary.
If the alignment bushings are missing, it will be difficult to shift, there will be clutch problems and 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 shaft splines (G 000 100).
It must be possible to slide the clutch plate back and forth on the input shaft.
To install the transmission, the (3282) must be equipped with the (3282/31).
- Install the (3282) to the (V.A.G 1383 A).
- Place the (3282/31) on the (3282) (adjustment plate only fits in one position).
- Align the arms on the (3282) so that they match up with the holes in the (3282/31).
- Install the support elements - A - as illustrated on the (3282/31).
- Install the (3282/45) instead of the support element - C -.
- Align the (3282/31) so that it is parallel to the transmission.
- Position the (V.A.G 1383 A) under the vehicle. The arrow symbol - B - on the (3282/31) points in direction of travel.
A = (3282/45) with an M8 collar nut.
- Install the M8 collar nut on the (3282/45) to secure the transmission.
- Carefully lift the transmission. Be careful of the power steering line.
- Push the engine forward slightly with a 2nd technician.
- Guide the transmission carefully past the flywheel - arrow 2 - and past the subframe - arrow 1 -.
• A second technician must continue to press the engine forward.
- Align the transmission with the engine and install it.
- Install the lower bolts for the engine to the transmission and tighten them to specification.
- Install the engine/transmission bolt - arrow - and tighten it to specification.
- Install the engine/transmission bolt - arrow - near the right side flange shaft and tighten it to specification. Use the (T10061).
- Install the cover plate - A - - arrows - and tighten the bolt to 10 Nm.
- After the transmission is attached to the engine, remove the (V.A.G 1383 A) from the transmission.
- Install the transmission mount to the transmission mount bracket using new bolts - arrows -.
- Align the engine/transmission into its installed position. Tighten both spindles on the (10-222 A).
- Install new bolts - arrows - for the engine mount to engine mount bracket and tighten to tightening specification.
CAUTION!
Only remove the (10 - 222 A) when the bolts for the engine and transmission mounts are tightened to specification.
- Install the upper bolts for attaching the engine to the transmission and tighten them to specification.
- Install the pendulum support.
- Use new bolts.
• Install the engine/transmission mounts free of tension.
- Attach the drive axles to the transmission.
- Install the drive axle heat shield and bolts - arrows -, if equipped.
- Assemble the exhaust system and attach the exhaust system bracket to the subframe.
- Install the bolt - 3 - and the nut - 2 - and install the starter.
- Connect the connector - 1 - to the backup lamp switch (F4).
- Install the clutch slave cylinder and tighten the bolts - arrows - to specification, see - item 9 -=> [ Bolt ] Clutch Release Mechanism Overview.
- Press the line between the master cylinder and slave cylinder - A - into the bracket - B -, if present, on the transmission.
- Attach the ground cable to the upper bolt on the starter.
- Attach the cable bracket support to the transmission and tighten the bolts - arrows - to specification, see - item 6 -=> [ Bolt ] Shift Mechanism Overviews.
- Install the shift lever - B -, refer to => [ Installing the Transmission
Shift Lever ] Shift Mechanism Overviews and tighten the nut - arrow 2 - to specification, see - item 17 -=> [ Self Locking Nut ] Shift Mechanism Overviews.
• Lubricate the bearing areas and sliding surfaces when installing.
• For the correct grease for the gearshift mechanism, refer to the Parts Catalog.
- Install the relay lever - A - and the cable retainer. Refer to => [ Plastic Relay Lever ] Plastic Relay Lever.
- Lubricate the pin on the shift lever with a small amount of grease - A -.
- Attach the shift cable to the shift lever - arrow 1 - and install a new locking washer.
- Adjust the shift mechanism. Refer to => [ Shift Mechanism, Adjusting ] Adjustments.
- Check the transmission fluid level. Refer to => [ Transmission Fluid, Checking ] Service and Repair.
If the transmission touched any other components, then repair any damaged surfaces. Refer to the Paint Repair Information.
- Install the plenum chamber cover.
- Install the battery tray and the battery.
- Install the air filter.
- Connect the battery and follow the procedure regarding what to do after connecting the battery.
- Install the left front wheel housing liner.
- Attach the noise insulation.
Tightening Specifications
Transmission to Engine
- A - alignment bushings for centering
Transmission Mount to Transmission
- Replace the bolts.
Engine Mount to Engine Mount Bracket
- Replace the bolts.
- Tighten all bolts hand tight.
- Tighten the bolts to specification.
Drive axle to flange shaft.