Transmission, transporting

Special tools, testers and auxiliary items required 

Fig 1: Transmission Support Jig. 3336

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• 3336 transmission lifting beam

Transmission lifting beam can be used to transport transmission and when setting up transmission support 3282.

Fig 2: Bolting Transmission Support Jig. 3336 To Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Bolt transmission lifting beam 3336 to clutch housing.

Fig 3: Adjust Support Jig On Sliding Piece Using Locking Pin

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Set support arm in slide with locking pin (arrow).

• No. of holes visible = 17

• Lift transmission with workshop crane and transmission lifting beam 3336.

Installing 

Install in reverse order, paying attention to the following:

• Clean input shaft splines and lightly grease with G000 100 grease.

The clutch plate must slide easily back and forth on input shaft.

• Lightly coat contact surface on push rod at clutch release lever with copper grease, e.g. Z 381 351 TE.
• Check whether dowel sleeves for centering engine and transmission in cylinder block have been installed.
• If installed, make sure that intermediate plate is correctly positioned on engine.
• Check clutch release bearing for wear and replace.

Fig 4: Servicing Release Bearing With Plastic Ring

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• If plastic ring on release bearing is detached, adhere this back onto bearing ring with adhesive AMV 195 KD1 01.

Three right-angled lugs -arrows- on plastic ring engage in the recesses on bearing ring.

If ridges are deeper than 0.5 mm, replaced release bearing.

• All threaded holes into which self-locking bolts are installed, must be cleaned of locking fluid residue with a thread tap.
• Replace all self locking nuts.

Fig 5: Identifying Clutch Slave Cylinder Bracket And Fastener

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Lift transmission until clutch slave cylinder with bracket for hose and line can be installed (arrow).
• Install lower engine, transmission and starter mounting bolts and install starter.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Fig 6: Drive Shafts And Flange Shafts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install tunnel cross member onto transmission mount -4-.
• Install tunnel cross member onto body. First install bolts -3- and then bolts -2-.
• Check shift mechanism adjustment, adjust. Refer to Shift mechanism, adjusting .
• Align exhaust system stress-free:

Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS

• Checking oil level in manual transmission. Refer to Oil level in manual transmission, checking .
• Read battery CAUTION! note. Refer to Shift mechanism, servicing .
• Connect battery.
• After connecting battery, enter anti theft code for radio.

Refer to Operating instructions for radio

Refer to

• 01 - MAINTENANCE
• 01 - MAINTENANCE for Cabriolet

Tightening torques 

Fig 7: Identifying Engine/Transmission Mountings (Automatic/Manual Transmission)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Attachment of 4-cylinder engine to transmission

A: Dowel sleeves for centering

1) Always replace bolt with washer

1) Replace bolt.