Transmission, Installing: Installing

NOTE:

Replace bolts that are tightened to the specification. The aluminum bolts for attaching the engine to the manual transmission may be used two times.

Replace bolts that are tightened to the specification.

Replace self-locking nuts and bolts and seals, gaskets and O-rings.

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 the same positions.

Check the input shaft near the bearing in the drive plate -arrow- for scoring. Replace the needle bearing in the drive plate, if necessary INPUT SHAFT OVERVIEW - Needle Bearing .

Fig 1: Checking Input Shaft For Wear

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Transmission Installation Tightening Specifications: TIGHTENING SPECIFICATIONS 

-- Check if the alignment sleeves -A- for centering the engine/transmission are in the cylinder block and insert them if they are not.

Fig 2: Removing Starter Off Transmission And Leave It In Installation Position

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• See if it is possible to use the aluminum bolts -2 through 11- again and mark them, if necessary. CHECK THE ALUMINUM BOLTS -2 THROUGH 11- TO SEE WHETHER THEY CAN BE REUSED. .

-- Install the clutch module, if necessary. Refer to CLUTCH MODULE .

Fig 3: Sliding Torque Converter Carefully Onto Input Shaft

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-- Mount the transmission onto the T40173 and secure it using the tension strap -1- as illustrated.

Fig 4: Identifying Transmission Holding Fixture

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-- The following preparations must be made before connecting the engine and transmission:

Fig 5: Inserting Assembly Aid T40169 Into Transmission Housing And Flywheel From Below

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-- Insert the T40169 in the transmission housing and the clutch module from below as shown in the illustration.

• The T40169 must engage in the semi-circular opening -1- and into the check hole -2-.

-- Install the bolts from the T40169 into the holes on the transmission housing.

-- Insert the T40170 in the transmission housing from below and secure it on the flange shaft -1-.

Fig 6: Identifying Transportation Lock T40170

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-- Raise the transmission straight up until the clutch slave cylinder can be inserted.

Fig 7: Identifying Bolt And Clutch Slave Cylinder Secured Sideways In Engine Compartment

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-- Tighten the bolt -2-. Tightening specification CLUTCH HYDRAULICS OVERVIEW .

NOTE:

The next step is only necessary if a drive plate with alignment pins -2- is installed.

Fig 8: Aligning Drive Plate To Clutch Module

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-- Also align the drive plate to the clutch module so the alignment pins -2- on the drive plate (if applicable) can engage in the larger holes -1- on the clutch module.

-- Attach the transmission to the engine and tighten the bolts -3 through 11-. For the correct tightening specifications, refer to TIGHTENING SPECIFICATIONS .

Fig 9: Removing Starter Off Transmission And Leave It In Installation Position

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-- Raise the transmission using the V.A.G 1383 A until dimension -a- is reached between the subframe and the body.

Fig 10: Raising Transmission

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• Dimension -a- = maximum 100 mm.

-- Install the starter and tighten the bolts -1- and -4-. Tightening specification TIGHTENING SPECIFICATIONS .

Fig 11: Disconnecting Starter Electrical Connector

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-- Tighten the right catalytic converter EXHAUST SYSTEM, EMISSION CONTROLS .

-- Attach the push rod -1- SELECTOR MECHANISM OVERVIEW .

Fig 12: Identifying Bolts For Selector Rod And Push Rod

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-- Attach the connecting rod -3-. Tightening specification SELECTOR MECHANISM OVERVIEW .

-- Connect the connector -2- to the transmission range gear recognition switch -F208-.

-- Attach the connector to the engine speed sensor -G28-.

-- Install the transmission shift lever -2- as follows:

Fig 13: Gearshift Lever Can Be Attached To The Gearshift Shaft In Only One Position

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• The gearshift lever -2- can be attached to the gearshift shaft -1- in only one position (gap in the splines -arrow-).

-- Attach the transmission shift lever -2-. Tightening specification SELECTOR MECHANISM OVERVIEW .

-- Install the left and right drive axles on the transmission flange shafts. Refer to DRIVE AXLE .

-- Tighten the heat shield bolts -arrows- to 23 Nm. 

Fig 14: Driveshaft Heat Shield - Tightening Specification

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-- Loosen the 10 - 222 A spindles.

-- Lift the transmission and tighten the tunnel crossmember bolts -arrows-. For the correct tightening specifications, refer to TUNNEL CROSSMEMBER, TRANSMISSION MOUNT AND TRANSMISSION SUPPORT OVERVIEW .

Fig 15: Identifying Bolts & Tunnel Crossmember

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-- Remove the V.A.G 1383 A and the T40173 from the transmission.

-- Remove the 10 - 222 A.

-- Mount or install the driveshaft on the transmission. Refer to DRIVESHAFT, REMOVING FROM REAR FINAL DRIVE or DRIVESHAFT ATTACHED ON TRANSMISSION SIDE .

Fig 16: Holding Driveshaft Using T10172

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-- Re-assemble the exhaust system and ensure it is not under stress EXHAUST SYSTEM, EMISSION CONTROLS .

Tightening Sequence - Clutch Module to the Drive Plate 

-- Remove the T40169 and T40170.

-- Put in sixth gear; to do this, move the gearshift shaft -1-, push the gearshift lever -2- forward in direction of -arrow-.

Fig 17: Identifying Gearshift Assembly

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-- Mount both front wheels.

Use the T10172 and adapter T10172/5 to block the driveshaft to keep it from turning, too.

Fig 18: Holding Driveshaft Using T10172

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-- Turn both front wheels together in one direction until the clutch module turns one complete turn (360°).

• The check hole -arrow- must be visible in the transmission housing cut-out.
  Fig 19: Locating Transmission Housing Check Hole

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Tighten the clutch module to the drive plate as follows:

Fig 20: Identifying Clutch Module First Bolt Installation Location

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• Use new bolts.
• Tightening Specification CLUTCH MODULE OVERVIEW .
• Tighten the bolts using the V.A.G 1332/14.

-- Install the first bolt -arrow- and tighten by hand (2 Nm  ).

-- Continue turning the clutch module/drive plate 180° via the front wheels.

-- Insert the second bolt and tighten it to the specification CLUTCH MODULE OVERVIEW .

-- Insert the remaining connecting bolts connecting the clutch module to the drive plate and tighten them to the specification immediately (including the first bolt installed) CLUTCH MODULE OVERVIEW .

-- Tighten the universal joint -arrow- to the steering gear. Refer to STEERING COLUMN, HANDLING AND TRANSPORTING .

Fig 21: Pressing CV Joint Off Steering Gear And Slide It Up

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-- Install the power steering hydraulic oil lines. Refer to DESCRIPTION AND OPERATION .

-- Install the subframe crossbrace. Refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

-- Fill the power steering with hydraulic oil. Refer to POWER STEERING FLUID LEVEL, CHECKING .

-- Gear oil level in manual transmission, checking. Refer to MANUAL TRANSMISSION, CHECKING TRANSMISSION FLUID LEVEL .

-- Tighten down both front wheels using tightening torque. Refer to WHEEL BOLT TIGHTENING SPECIFICATIONS .

-- Observe measures after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .