Transmission, Installing

Transmission, Installing

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

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

- Clean any locking fluid residue from all threaded holes using a tap.

- 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 is engaged on the sealing flange and is pushed onto the alignment sleeves - arrows -.






- 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.

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

To install the transmission the adjustment plate (3282/33) must me 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 pin (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 in the transmission for the pendulum support bolt.

- Secure the adapter for VW 771 slide hammer (VW 771/40) inside the threaded hole in the transmission housing as illustrated.






- Secure the transmission to the transmission support (3282) with an M10 x 20 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 drive direction.

• Pay attention to the lines when installing the transmission.

- Lift the transmission carefully.

• The right flange shaft must be guided past the flywheel - arrow 2 -; pay attention to the intermediate plate - arrow 1 -.






- The right flange shaft - 1 - must be guided over the engine bolt flange - 2 -.






- Change the position of the transmission using the transmission support (3282) spindles so that it does not come in contact with the longitudinal member - arrows -.






- 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.

- Insert the engine/transmission bolt - C - and tighten 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.

- Install the engine/transmission bolt - arrow - and tighten it 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.

- Attach the shift lever to the gear shift shaft, refer to => [ Installing the Transmission Shift Lever ] Shift and Selector Cables Overview and tighten the nut to specification, see - item 15 - in the => [ Shift and Selector Cables Overview ] Shift and Selector Cables Overview.

• Grease the bearing areas and sliding surfaces on the relay lever and shift lever, refer to => [ Lubricating the relay lever. ] Shift and Selector Cables Overview and to => [ Lubricating the Transmission Shift Lever ] Shift and Selector Cables Overview. Grease allocation, refer to the Parts Catalog.

- Install the relay lever and cable retainer - arrow 2 - all the way into the gear shift unit cover.






- Install the clip - arrow 1 - and make sure it is locked into place.

- Install the transmission mount bracket - 1 - with the new bolts to the transmission and tighten the bolts - arrows - to specification. Refer to => [ Engine and Transmission Mounts Overview ] Description and Operation.






- 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 -.






Risk of damaging threads in the transmission mount bracket by inserting bolts crooked.

• The transmission mount bracket - 1 - and the transmission mount support arm - 2 - must be absolutely parallel to each other before installing the bolts - arrow -. If necessary, lift the back of the transmission using the engine-/gearbox jack.

• Install the engine/transmission mount free of tension.

- Install the new bolts - arrows - for the transmission mount - 2 - to the transmission mount bracket - 1 - and tighten them to specification. Refer to => [ Engine and Transmission Mounts Overview ] Description and Operation.

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

- Attach the drive axles to the transmission.

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






- Install the subframe with steering gear.

• There are threaded inserts (for example, a "Heli Coil") in the pendulum support bolt hole in the transmission.

• How to recognize: There is a shoulder - arrow - at the first thread.






• Tighten the bolts to the specification.

- Install the pendulum support with new bolts.






- Assemble exhaust system and fasten exhaust system suspended mount bolts to the subframe.

- Position the starter and install the lower bolt.

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

- Install the starter bolt and then connect the connector and wires to the starter.

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






- Connect the backup lamp switch connector - 2 -.

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






- Pull on the hose/line or pipe to make sure it is secure.

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

- Bend the supply hose back into its original shape after removing the hose clamp up to 25 mm dia. (3094).

- Bleed the hydraulic system. Refer to => [ Hydraulic System, Bleeding ] Procedures.

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

- Attach the cable bracket to the transmission and tighten the bolts/nut - arrows - to specification, see - items 8 and 19 - in the => [ Shift and Selector Cables Overview ] Shift and Selector Cables Overview.






- Apply a small amount of grease on the pin - arrow - on the shift lever - 1 -.






• Grease allocation, refer to the Parts Catalog.

- Secure the shift cable - 2 - to the shift lever with a new lock washer - 3 -.

- Install the selector cable into the cable retainer on the relay lever.

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

- Install the plenum chamber cover.

- Tighten the left and right lock carrier bolts - arrows - for the carrier.






- Install the battery tray and the battery.

- Attach the charge air hose to the turbocharger and secure it with the bolt - 2 -.






- Attach the crankcase ventilation hose - 1 - and clip the vacuum hoses to the charge air hose - arrows -.

- Connect the connector on the crankcase ventilation hose - 1 -.

- Install the air filter housing.

- Install the engine cover.

- Connect the battery and follow the procedure regarding what to do after connecting the battery.

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

- Install the left and right front wheel housing liners..

- Install the noise insulation.

- Install the front wheels.