Installing transmission: Notes

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Installation is in reverse order of removal, note the following:

NOTE:

Before installing a replacement transmission, clean ATF lines and ATF cooler → ATF lines and ATF cooler, cleaning .
When performing repairs, replace self-locking nuts and bolts.
Always replace bolts that are secured with tightening torque as well as seals, gaskets and O-rings.
Clean input shaft splines of transmission and damper unit splines on flywheel, remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Excess grease must be removed.
Secure all hose connections with hose clamps of the same type as those equipped by the factory .
When installing, bring all cable ties back to same positions.

Check if alignment sleeves for centering engine/transmission are in cylinder block, and install if necessary.
Before installing transmission, tie electrical wiring to one side so that it cannot be trapped between engine and transmission.
Raise engine far enough until selector lever cable can be installed.

Fig 1: Pressing Selector Shaft Lever On Transmission Completely Toward Rear

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press selector shaft lever - A - on transmission completely toward rear - arrow - until parking lock engages.

Fig 2: Removing Support Bracket For Selector Lever Cable

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Carefully press ball socket of selector lever cable - 2 - onto lever for selector rod.

NOTE:

Take care not to bend selector shaft lever when pressing it on; support it if necessary, as otherwise selector mechanism can no longer be adjusted properly.

Fig 3: Removing Bracket For Selector Lever Cable By First Removing Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If bracket for selector lever cable - 3 - was removed from transmission:

Tighten bolts - 2 - on bracket - 3 - for selector lever cable to 23 Nm on transmission.

NOTE:

Do not bend or kink the selector lever cable.
Lightly grease ball socket of selector lever cable with polycarbamide grease G 052 142 A2 before installing.

Fig 4: Removing Support Bracket For Selector Lever Cable

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install support bracket for selector lever cable - 1 - according to marking on bracket.
Place intermediate panel or intermediate plate onto bushings.

Fig 5: Moving Engine/Transmission Jack V.A.G 1383 A With Transmission Mount 3282 Under Transmission And Support Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Carefully raise transmission and bring into installation position using transmission support 3282.

NOTE:

Tightening torques are valid only for nuts and bolts that are lightly greased, oiled, covered with a thin coat of phosphate or blackened, tightening torques Securing engine/transmission (transmission flange pattern) .
Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant.
Do not use degreased parts.
Tolerance for torque specification ± 15%.

Tighten connecting bolts on engine/transmission flange to tightening torque (tables Securing engine/transmission (transmission flange pattern) ).

Fig 6: Swivel Stabilizer Bar Nuts, Engine Mountings Nut And End Of Stud

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten nuts for left and right engine mounts - 3 - →
- 10 - ENGINE - ASSEMBLY for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
- 10 - ENGINE - ASSEMBLY for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
- 10 ENGINE - ASSEMBLY for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
- 10 - ENGINE - ASSEMBLY for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
- 10 - ENGINE - ASSEMBLY for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
- 10 - ENGINE - ASSEMBLY for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF
.
Tighten stabilizer bolts - 2 - → 40 - FRONT SUSPENSION .
Tighten bolts of torque support or torque support stop to engine →
- 10 - ENGINE - ASSEMBLY for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
- 10 - ENGINE - ASSEMBLY for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
- 10 ENGINE - ASSEMBLY for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
- 10 - ENGINE - ASSEMBLY for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
- 10 - ENGINE - ASSEMBLY for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
- 10 - ENGINE - ASSEMBLY for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF
.

Fig 7: Removing Bolts And Transmission Support From Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Bolt transmission mount - 1 - onto transmission with bolts - 2 - → Transmission mount, transmission support and tunnel cross member, removing and installing
Install ATF lines with new sealing rings → ATF lines, ATF cooler and auxiliary ATF filter, servicing .
Install exhaust system →
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
- 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF
.
Install drive axles → 40 - FRONT SUSPENSION .

Install heat shield for left and right drive axle.
Install tunnel cross member → Transmission mount, transmission support and tunnel cross member, removing and installing .
Align exhaust system so it is free of tension →
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
- 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF
.
Electrical connections and routing → Electrical Wiring Diagrams, Troubleshooting and Component Locations.

Observe procedures for connecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.
Check adjustment of selector lever cable → Selector lever cable (through VIN 8E_6A156499), adjusting .
Check oil level in front final drive → Gear oil level in front final drive, checking .
Check ATF level and top off → ATF level, checking and topping off .