Transmission, Installing

Transmission, Installing

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

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






- 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).

- 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 the clutch release bearing for wear, replace if necessary.

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 - to the adjustment plate - C - ( pin (3282/29) ) 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) in the rear opening for the pendulum support bolt on the transmission.






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

- Remove from a new transmission or replacement transmission the right flange shaft - arrow -.






• Check the seal for leaks before removing the flange shaft. If the seal has leaks, replace it when installing.

• => [ Left Flange Shaft and Seal ] Left Flange Shaft and Seal

• => [ Right Flange Shaft and Seal ] Right Flange Shaft and Seal

• If the transmission fluid leaks out while removing the flange shaft, drain and refill the installed transmission and the installed flange shaft. Refer to => [ Transmission Fluid, Draining and Filling ] Transmission Fluid, Draining and Filling.

- Attach the spindle - A - for the seal installer set - rear diff (3066) into the threaded piece on the differential.






- Insert the thrust piece (T10148) and secure it with the nut - B -.

• The thrust piece (T10148) should protect the right seal and the transmission from dirt.

• A M8 x 105 mm bolt may be installed by hand into the differential threaded piece instead of the spindle - A -.

- Carefully lift the transmission. Be careful of the power steering line.

- Tip the transmission over the adjusting spindle for the transmission support (3282) in the - direction of the arrow -.






- Push the engine forward slightly with help from a 2nd technician.

- Carefully lift the transmission with the engine-/gearbox jack (V.A.G 1383 A) , while making sure that the right flange shaft - 1 - is guided through without any damage to the pressure plate - arrow -.






• Guide the transmission through when lifting it at the power steering line and with the left flange shaft - B - on the subframe - arrow -.






- Align the transmission with the engine and install it.

- Install the lower bolts - 5 and 6 - for the engine to transmission and tighten them to specification. Refer to => [ Transmission to Engine Bolt Tightening Specifications ] Transmission to Engine Bolt Tightening Specifications.






- Reinsert the right flange shaft and tighten the bolt - arrow - to specification, see - item 10 - in the => [ Differential Overview ] Description and Operation.






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

- Install the upper bolts - 1 and 2 - for the engine to transmission and tighten them to specification. Refer to => [ Transmission to Engine Bolt Tightening Specifications ] Transmission to Engine Bolt Tightening Specifications.






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






- Align the engine/transmission in its installed position. Lift until the transmission mount bracket is touching the transmission mount completely.






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

• Before installing the bolts - arrows -, the transmission mount bracket and transmission mount support arm must be absolutely parallel to each other. If necessary, lift the back of the transmission with the engine-/gearbox jack.

• Install the transmission mount free of tension.

- Install new bolts - arrows - for the transmission mount to transmission mount bracket 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 the bolts for the transmission mount/bracket are tightened to specification.

- Install the clutch slave cylinder and tighten the bolts - arrows B - to specification, see - item 15 - in the => [ Clutch Hydraulic System Overview ] Removal and Replacement.






- Install the transmission support and bolts - arrows A - and tighten them to specification. Refer to => [ Engine and Transmission Mounts Overview ] Description and Operation.

- Attach the drive axles to the transmission.

- Install the right drive axle heat shield and bolts - arrows -.






- Attach the left ball joint to the left control arm and install the nuts - arrows -.






- Attach the left coupling rod - 3 - to the stabilizer bar - 2 -.






- Install the pendulum support with new bolts.






- Install the front exhaust pipe suspended mount bolts - arrows - to the subframe and connect the front exhaust pipe with the front muffler.






- Align the exhaust system free of tension.

- Install the starter.

- Attach the wire mount to the lower starter bolt and nut - 1 - and tighten it to specification. Refer to => [ Transmission to Engine Bolt Tightening Specifications ] Transmission to Engine Bolt Tightening Specifications.






- Connect the backup light switch connector - 3 -.

- Attach the clamps - arrows - for the power steering line to the transmission.






- Attach the ground cable to the upper starter bolt and tighten the nut - arrow - to specification. Refer to => [ Transmission to Engine Bolt Tightening Specifications ] Transmission to Engine Bolt Tightening Specifications.






- Install the cable bracket - 1 - to the transmission and tighten the bolts - arrows - to specification, see - item 15 - in the => [ Shift and Selector Cables Overview ] Shift and Selector Cables Overview.






- Secure the hose/line assembly bracket - 1 - to the transmission with the bolt - 3 -.






- Press the hose/line assembly - 2 - into the bracket - 1 -.

- Install the shift lever - A -.






- Tighten the nut - arrow 3 - to specification, see - item 6 - in the => [ Shift and Selector Cables Overview ] Shift and Selector Cables Overview.

• Grease the relay lever before installation, refer to => [ Relay Lever, Lubricating ] Shift and Selector Cables Overview.

• For the correct grease, refer to the Parts Catalog.

- Insert the relay lever together with the cable retainer and secure them with the clip - arrow 1 -.

- Coat the pin on the shift lever - A - with a small amount of grease.

- Install the shift cable to the shift lever - A - and secure it with new lock washer - arrow 2 -.

- Connect the selector cable to the cable retainer.

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

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

- Install the transport strap to the lifting eye on the engine - arrow A - and tighten the bolt - arrow B -.






- Install the plenum chamber cover.

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






- Install the battery tray and the battery.

- Install the engine cover with air filter.

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

• If necessary, after installing the transmission, apply corrosion protection to the subframe.

• If when removing the flange shaft, the transmission fluid leaked out, drain and fill the transmission fluid for the installed transmission. Refer to => [ Transmission Fluid, Draining and Filling ] Transmission Fluid, Draining and Filling.

- Install the left front wheel housing liner..

- Install the noise insulation.

- Install the wheels.