Transmission, Installing

Transmission, Installing

• Refer to the "Transmission, Removing" procedure for the required special tools.

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






Perform the following

- 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 plate 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 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 in the transmission for the pendulum support bolt.






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

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






- Check the flange shaft seals for leaks and replace, if necessary. Refer to one of the following:

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

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

- Install the spindle - A - from the seal installed set - rear diff (3066) into the threaded piece on the differential.






- Insert the thrust piece (T10148) and secure 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 a the spindle - A -.

- Tip the transmission in the- direction of the arrow -, using the adjusting spindle on the transmission support (3282).






- Carefully lift the transmission with the engine-/gearbox jack (V.A.G 1383 A) , while making sure that the seal - 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 on the subframe.

- Align the transmission with the engine and install it.

- Install the lower transmission to engine bolts and tighten them to specification. Refer to => [ Transmission to Engine Tightening Specifications ] Fastener Tightening Specifications - Controls, Housing.

- Install the right flange shaft and tighten the bolt - arrow - to specification, see - item 10 - in => [ Differential ] Service and Repair.






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

- Install the small cover plate - 2 - , if equipped and tighten the bolt - 1 -.






- Install the upper transmission to engine bolts and tighten them to specification. Refer to => [ Transmission to Engine Tightening Specifications ] Fastener Tightening Specifications - Controls, Housing.

- Install the transmission mount bracket - A - to the transmission using new bolts - arrows - and tighten them to specification. Refer to => [ Engine and Transmission Mount Overview ] Service and Repair.






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






Risk of damaging the threads in the transmission mount bracket by installing 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 using the engine-/gearbox jack.

- Install the new transmission mount to transmission mount bracket bolts - arrows - and tighten to specification. Refer to => [ Engine and Transmission Mount Overview ] Service and Repair.

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

• Install the engine/transmission mount free of tension.

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






- Install the transmission support and tighten the bolts - A arrows - to specification. Refer to => [ Engine and Transmission Mount Overview ] Service and Repair.

- Install the drive axles to the transmission.

- Install the right drive axle heat shield and bolts - arrows -, if it was removed earlier.






- Install the pendulum support with new bolts - arrows A, B and C -.






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

- Attach the power steering line clamps to the transmission.

- Install the starter.

- Tighten the nut - 1 - on the bracket.






- Connect the connector - 3 - to the backup light switch (F4).

- Attach the ground cable to the bolt at the top of the starter.

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






- Install the bracket - 1 - for the hose/line assembly and tighten bolt - 3 - to the transmission.






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

- Install the transmission shift lever - A -.






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

• Grease the relay lever before installation, refer to => [ Relay Lever, Lubricating ] Shift Mechanism Overviews.

• 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 transmission shift lever - A - with a small amount of grease.

- Install the shift cable on the transmission shift lever - A - and secure it with a 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.

- Insert the transport strap in the engine lifting eyes - arrows A and B - and tighten it.






- Install the plenum chamber cover.

- Install the lock carrier trim and the bolts - arrows - for the left and right front end brackets. Refer to "Lock Carrier" in






- Install the battery tray and the battery.

- Install the air filter housing.

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

- Install the left front wheel housing liner.

- Install the noise insulation.

- Install the wheel.