Installing Transmission

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Mounting plate 9725 must be secured to the manual transmission.

Fig 1: Mounting Plate On Transmission
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Support the transmission with engine and gearbox jack V.A.G 1383 A WE 1082 -1- and secure with a retaining strap -2- .

Fig 2: Supporting Transmission And Engine With Gearbox Jack
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Run in transmission.
Screw in fastening screws for securing transmission to engine. To do this, screw in and tighten four screws on the engine side and six screws on the transmission side.

Fig 3: Identifying Fastening Screws
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1. M12 x 60 → Tightening torque: 80 Nm (59 ftlb.)
2. M12 x 60 → Tightening torque: 80 Nm (59 ftlb.)
3. M10 x 50 → Tightening torque: 45 Nm (33 ftlb.)
4. M12 x 140 → Tightening torque: 80 Nm (59 ftlb.)
5. M12 x 140 + M12 nut → Tightening torque: 80 Nm (59 ftlb.)
Place a suitable wooden block under the transmission bell housing.

Fig 4: Supporting Transmission
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Mounting plate 9725 can now be removed from the manual transmission.

Fig 5: Mounting Plate On Transmission
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Install the starter. → Installing Starter
Screw in line bracket for B+ line.

Fig 6: Locating Holder For B+ Line
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Fit vent line on the transmission.

Fig 7: Locating Transmission Vent Line
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Attach cable plug for reversing light switch.

Fig 8: Reversing Light Switch
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Plug in cable plug for neutral switch at the top of the shift cover.

Fig 9: Locating Neutral Switch
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Install transfer gear. To do this, screw in the fastening screws. → Initial tightening: 20 Nm (15 ftlb.) → Final tightening: 90°

Fig 10: Identifying Transfer Gear Screws
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Information

Always observe the exact work sequence when installing/removing the transmission cross member.

Information

Always observe the exact work sequence when installing/removing the transmission cross member.

Information
- Screws which are tightened with a torque angle must be replaced with new ones .
Screw in two fastening screws -2- for securing the transmission cross member to the holder on the transfer gear. → Initial tightening: 50 Nm (37 ftlb.) → Final tightening: 90°

Fig 11: Identifying Transmission Cross Member And Fastening Screws
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Screw in four fastening screws -1- for securing the transmission cross member to the body. → Initial tightening: 50 Nm (37 ftlb.) → Final tightening: 90°

Fig 12: Identifying Transmission Cross Member And Fastening Screws
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Insert clutch slave cylinder and screw in fastening screw. → Tightening torque: 10 Nm (7.5 ftlb.)

Fig 13: Locating Clutch Slave Cylinder
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Secure coolant line at the side of the transmission. → Tightening torque: 10 Nm (7.5 ftlb.)

Fig 14: Locating Coolant Pipe On Transmission
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Plug in cable plug on the transfer gear control unit.

Fig 15: Locating Transfer Gear Control Unit
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Install exhaust system holder -inset- . → Tightening torque: 23 Nm (17 ftlb.)

Fig 16: Identifying Exhaust System Bracket And Fasteners
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Replace circlip -1- and O-ring -2- on transfer gear flange.

Fig 17: Identifying Circlip On Flange
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Fit rear cardan shaft on the transfer gear. To do this, slide the cardan shaft onto the flange until it engages securely.
Press ends of cables -2- onto the ball heads of the external shift mechanism and fit locking elements -1- on the support.

Fig 18: Identifying Cable Connection On Transmission
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