Transmission

Transmission

=> [ Removing ]

=> [ Installing ]

Special tools, testers and auxiliary items required

• Adapter (VW 771/40)

• Engine Support Bridge (10-222 A)

• Engine Support Feed (10-222 A/8)

• Hose Clamps up to 25 mm Dia. (3094)

• Transmission Support (3282)

• Adjustment Plate (3282/33)

• Pin (3282/29)

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

• Transmission Support Jig (3336) for transporting the transmission

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

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

• Engine/Transmission Jack (V.A.G 1383 A)

• Grease for clutch disc shaft splines (G 000 100)

• Allocate the grease for the shift mechanism.

• M10 x 20 Bolt

Removing

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

- Disconnect the battery Ground (GND) cable with the ignition turned off.

Later in the procedure, the (10-222 A) is connected to the engine lifting eyes.

- Remove the engine cover if it is blocking the lifting eyes.

- Remove the air filter housing, if it is located near the battery.

- Remove the battery, cover and tray.

- Remove the shift cable lock washer - 3 - from the transmission shift lever - 1 - and remove the cable from the pin - arrow -.





Metal Relay Lever

- Remove the selector cable retaining washer - 4 - from the relay lever - 2 - and remove the cable from the pin - arrow -.

Plastic Relay Lever

Disconnecting the cable retainer from the selector cable





• To avoid damage to the selector cable, the cable retainer must be disconnected from the selector lever before removal.

- Pull the securing mechanism forward as far as the stop in the direction of - arrow 1 - and then unlock to the left in the direction of - arrow 2 -.

- Then press the relay lever forward (- direction of arrow 3 -).

- The plastic relay lever is removed together with the cable retainer later in the procedure.

Continuation for All

- Remove the cable mounting bracket bolts - arrows - from the transmission, move it aside and tie it up.





- Clamp off the supply hose to the master cylinder using the (3094).





- If a hose/line assembly or plastic line is installed, clamp off the hose - A - to the slave cylinder using the (3094).





- Remove the clip - arrow - for the hose/line assembly or plastic line as far as the stop.

- Disconnect the hose/line assembly or plastic line from the breather/slave cylinder and seal it off.

CAUTION!
The clutch pedal must no longer be operated.

- Remove the ground cable - 1 - from the top starter bolt.





- Disconnect the electrical harness connector - 2 - from the back up lamp switch (F4).

- Disconnect the connector and wire from the starter.

- Remove the upper engine/transmission bolts - arrows -.





- Remove the starter upper bolt.

- Remove the foam piece on the upper edge of the left and right fenders.

- Disconnect any hoses and cables in the area of the lifting eyes on the engine.





- Install the (10-222 A) with the (10-222 A /8) in front of the engine hood support.

- Hook the spindle into the left lifting eye on the engine.

- Slightly tension the engine/transmission using the spindle.

- Loosen left and right front drive axle bolts.

- Raise the vehicle.

- Remove the front wheels.

- Remove the noise insulation.

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





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

- On vehicles with the start/stop system: disconnect the connector - arrow - from the transmission neutral position sensor (G701).





- Remove the bracket from the starter.

- Remove the starter.

- Disconnect the charge air hose connections - arrows 1 and 2 -.





- Remove the exhaust system suspended mount bolts - arrows - from the subframe.





- Disconnect the exhaust system at the double clamp - arrows -.





- Tie up the exhaust pipe at the front.

- If installed, remove the support - 1 - for the exhaust system from the transmission - arrow - and front exhaust pipe.





- Remove the pendulum support.





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





- Remove the left and right drive axles from the flange shafts - A - on the transmission.





- Secure the drive axles using wire, do not damage the protective coating when doing this.

- Remove the left and right coupling rods from the stabilizer bar.

- Remove the ball joint to control arm nuts - arrows -.





- Before removing the subframe, locate its position.

- Remove the subframe with pendulum supports, stabilizer bar and control arms.

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





- Lower the transmission approximately 60 mm - a - by adjusting the spindle.





• When moving the engine/transmission assembly, be aware of the coolant hose between the engine and heater core; do not strain.

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





Metal Relay Lever





- Pull off the locking washer - arrow - from the actuator lever - 1 - and remove the actuator lever.

Plastic Relay Lever

- Remove the relay lever with the cable retainer. Refer to => [ Plastic Relay Lever ] Description and Operation.

Continuation for All

- Remove the transmission shift lever from the shift rod.

On some vehicles, the small cover plate - A - for the flywheel is difficult to access.





- On those vehicles, first remove the coolant pipes - B - from the engine - arrows -.

• Do not open the cooling system when doing this.

- Remove the small cover plate - A - for the flywheel - arrows -.





- Remove the lower engine/transmission bolts - 2 -.





• Loosen the engine/transmission bolt - 3 - and install it hand tight.

Ensure the (3282) is equipped with the (3282/33) to remove the transmission.

- Place the (3282) on the (V.A.G 1383 A).

- Align the arms of the (3282) according to the holes in (3282/33).

- Install the support elements - A - onto the (3282) as shown.





- Install the (3282/29) in place of attachment- C -.

- Place the (V.A.G 1383 A) under the vehicle, with the arrow symbol - B - on the (3282/33) pointing to the front of the vehicle.

- Align the (3282/33) parallel to the transmission.

- Secure the (VW 771/40) in the threaded hole of the transmission housing as shown in the illustration.





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

- Secure the transmission to the (3282) using bolt (MD) - A -.

When doing this, the drift - B - should stop at the bottom flush with the guide of the (3282) - arrow -.

- Remove the engine/transmission bolt - arrow -.





- Remove the last engine/transmission bolt (item - C -, see illustration N34-10359).

- Separate the transmission from the engine (centering sleeves).

- Rotate the transmission upward near the differential by adjusting the spindle on the (3282).

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





- Tilt the transmission to the left by adjusting the spindle on the (3282).

- Carefully lower the transmission.

• Be careful of the steering gear - 3 - when lowering the transmission.

• Pay attention to all lines when lowering the transmission.

Installing

• Refer to the procedure "Removing" for the required special tools. Refer to => [ Removing ].

• Replace the self locking nuts and bolts.

• Replace bolts that have been tightened to angle specifications.

• All cable ties that are opened or cut off during removal must be replaced in the same positions during installation.

• Clean the input shaft splines and (on used clutch plates) the hub splines. Remove any corrosion and apply a very thin coating of lubricant (G 000 100) to the splines. Then move the clutch plate back and forth on input shaft until the hub moves freely on the shaft. Excess grease must be removed.

- If the transmission is replaced, transfer the transmission shift lever and relay lever.

- All threaded bores in which self locking bolts are threaded must be carefully cleaned of remaining locking fluid using a tap.

- Make sure the centering sleeves for the engine to transmission are installed in the cylinder block, install them, if necessary.

If the alignment sleeves are not installed, difficulty in shifting, clutch problems and possibly noises from the transmission (loose gear chatter) may develop.

- Make sure that the intermediate plate is engaged on the sealing flange and has been slid onto the alignment sleeves - arrows -.





- Check the release bearing for wear. Replace the slave cylinder with release bearing, if necessary. Refer to => [ Slave Cylinder with Release Bearing ] Slave Cylinder With Release Bearing.

Ensure the (3282) is equipped with the (3282/33) to install the transmission.

- Align the arms of the (3282) according to holes in (3282/33).

- Install the support elements - A - onto the (3282/33) as shown.





- Install the (3282/29) in place of attachment - C -.

- Attach the transmission to the (V.A.G 1383 A).

- Align the (3282/33) and transmission parallel to one another.

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

- Secure the (VW 771/40) in the threaded hole of the transmission housing as shown in the illustration.





- Secure the transmission on the (3282) using bolt (MD) - A -.

When doing this, the drift - B - should stop at the bottom flush with the guide of the (3282) - arrow -.

- Place the (V.A.G 1383 A) under vehicle, with arrow the symbol on the (3282/33)pointing to the front of the vehicle.

- Using the spindle on the (3282), adjust the transmission so that the differential area is rotated upward.

- Lift the transmission. Be careful of the steering gear - 3 -.





• Pay attention to all lines when installing the transmission.

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

- Use the spindle on the (3282) to rotate the transmission to the installed position.

- Align the transmission to the engine (centering sleeves) and insert.

- Install the engine/transmission bolt - C - and tighten to specification.





- Install the engine/transmission bolt - arrow - and tighten to specification.





- Install the lower engine/transmission bolts and tighten to specification.

- After the transmission is bolted to the engine at the bottom, remove the (3282) from the transmission.

- Install the upper engine/transmission bolts and tighten to specification.

- Install the transmission selector lever to the selector shaft of the transmission, refer to => [ Transmission Shift Lever,
Installing ] Shift Mechanism Overview and tighten the nut - item 17 -=> [ Self Locking Nut ] Shift Mechanism Overview to specification.

Metal Relay Lever





- Insert the actuator lever - 1 - into the shift mechanism and clip in the locking washer - arrow -.

Plastic Relay Lever

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

Continuation for All

- Install the transmission mount bracket - 1 - to the transmission with new bolts - arrows - and tighten to specification.





- Align the engine/transmission in the installed position. To do so, raise the engine/transmission far enough until the bracket - 1 - makes contact completely with the transmission mount - 2 -.





- Install the new bolts - arrows - for the transmission mount - 2 - to bracket - 1 - and tighten to specification.

CAUTION!
Only remove the (10-222 A) when all the mount bolts are tightened to the specification.

- Install the small cover plate - A - for the flywheel behind the right flange shaft.





- If the coolant pipes - B - had been removed from the engine, install them again now - arrows -.

- Install the subframe/control arm and pendulum support.

• The holes for the pendulum support on transmissions from 28 May 07 have threaded inserts (for example "HeliCoil").

• How to recognize: collar on the first thread - arrow -.





• Note the correct bolts and tightening specifications.

- Install the pendulum support to the transmission.





- Install the drive axles to the transmission.

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





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





- Assemble the exhaust system and attach the secure the suspended mount to the subframe.

- If equipped, install the exhaust system support - 1 - and secure it to the transmission - arrow - and front exhaust pipe.





- Install the charge air hose.

- Install the starter and secure it with the lower bolt.

- Secure the bracket for the wires with the lower starter bolt.

- On vehicles with the start/stop system: connect the connector - arrow - to the transmission neutral position sensor (G701).





- Install the upper starter bolt and attach the connector and wiring to the starter.





- Secure the Ground (GND) strap - 1 - to the upper starter bolt.

- Connect the connector - 2 - to the backup lamp switch (F4).

- Connect the hose/line assembly or plastic line - A - to the breather/slave cylinder up to the stop and push the clip - arrow - downward.

- Pull on the line to check installation.





- Remove the (3094) from the hose/line assembly or plastic line.

- Remove the (3094) from the supply hose, bring the hose back to its original shape.

- Bleed the clutch system. Refer to => [ Clutch System, Bleeding ] Procedures.

- Install the cable mounting bracket on the transmission and tighten the bolts - arrows -- item 6 -=> [ Bolt ] Shift Mechanism Overview and nut - arrow -- item 10 -=> [ Nuts ] Shift Mechanism Overview- arrows - to specification.





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





- Replace the lock washer - 3 - after every disassembly.

Metal Relay Lever

- Apply a small amount of grease to the pin - arrow - of the relay lever - 2 -.

- Slide the selector cable onto the pin - arrow - and secure with the retaining washer - 4 -.

Plastic Relay Lever

- Insert the selector cable in the cable retainer.

Continuation for All

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

- Install the battery tray, cover and battery.

- If removed, install the entire air filter housing.

- Install the foam pieces to the upper edges of the left and right fenders.

- Install the engine cover if necessary.

- Connect the battery and observe the procedure after connecting the battery.

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

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

- Install the noise insulation.

- Install the wheels.

- Check the headlamp adjustment on vehicles with the front level control system sensor.

Tightening Specifications

Transmission to Engine Bolts









- A and B -: alignment bushings

- Replace the bolts - 1 through 5 -.

Small cover plate for flywheel to intermediate plate: 10 Nm.

Transmission Mount Bracket to Transmission Bolt





- Replace the bolts.

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

Transmission Mount to Transmission Mount Bracket Bolt





- Replace the bolts.

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

• Install the engine/transmission free of tension.