Install Transmission

Raise and guide in the transmission.
1. 1.1 Only tighten screws in the following sequence initially: -5, 1, 3, 6, 4, 2- .
  For the next step, it is important that the screws are not yet tightened!
2. 1.2 Position the transmission 15 mm away from the engine flange.
Fig 1: Transmission Flange On Engine Screws Tightening Sequence
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Threaded joint for transmission flange on engine

Install clutch slave cylinder.

2.1 Grease the clutch slave cylinder at the lubrication point -Arrows- using Kluber Syntheso Glep.

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Lubrication point on clutch slave cylinder

2.2 Position the clutch slave cylinder.
2.3 Only insert screws -1- first.

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Clutch slave cylinder

NOTE: Engine housing overload.

Risk of engine damage if housing breaks.
→ Observe specified loosening and tightening sequence!

→ Loosening sequence: Loosen screws from the bottom up.

→ Tightening sequence: Tighten screws from top to bottom.

Attach the transmission flange.
1. 3.1 Fit screws -4, 5, 3, 6- first, then -1 and 2- .
Fig 2: Transmission Flange On Engine Screws Tightening Sequence
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Threaded joint for transmission flange on engine
Secure the clutch slave cylinder.
1. 4.1 Check that the clutch slave cylinder is fitted correctly.
2. 4.2 Tighten screws -1- on the clutch slave cylinder.
  > Tightening torque 23 Nm (17 ftlb.)
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Clutch slave cylinder
Tighten all screws in the following sequence -4, 5, 3, 6, 1, 2- using >V.A.G 1332 - torque wrench, 40-200 Nm (30-148 ftlb.) , for example.
> Tightening torque 85 Nm (62.7 ftlb.)

Fig 3: Transmission Flange On Engine Screws Tightening Sequence
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Threaded joint for transmission flange on engine
Secure cable duct for B+ line.
1. 6.1 Position cable duct -A- .
2. 6.2 Screw in and tighten screws -1- .
  > Tightening torque 13 Nm (9.6 ftlb.)
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Securing B+ line
Install disc valve holder and connect vacuum line.
1. 7.1 Screw in and tighten fastening screw -1- on the holder.
  > Tightening torque 13 Nm (9.6 ftlb.)
2. 7.2 Connect vacuum line for disc valve -Arrows- .
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Disc valve holder and vacuum line

Install coolant hoses.

8.1 Position holder for coolant hoses -1- .

8.2 Screw in and tighten fastening screw -2- .

> Tightening torque 13 Nm (9.6 ftlb.)

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Holder for coolant hoses

8.3 Connect coolant hoses -1 and 2- and secure with spring band clamps -3 and 4- .

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Spring band clamps

8.4 Remove hose clamping pliers -3 and 4- .

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Hose clamping pliers

Connect cable plug for speed sensor -1- .

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Speed sensor
Install transmission support -6- and transmission bracket -2- .
1. 10.1 Position transmission support -6- and screw on and tighten new nuts -3- on the threaded pins.
  > Initial tightening 30 Nm (22.1 ftlb.)
  
  > Torque angle 60°
2. 10.2 Lift transmission using a transmission jack.
3. 10.3 Position transmission bracket -2- and fit and tighten new screws -1- .
  > Initial tightening 30 Nm (22.1 ftlb.)
  
  > Torque angle 60°
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Transmission support and transmission bracket
Remove transmission jack -1- from under the transmission and engine.
1. 11.1 Loosen restraining strap.
2. 11.2 Lower and remove the transmission jack -1 and 2- .
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Transmission jack
Connect cable plug for temperature sensor to the transmission.
1. 12.1 Connect cable plug for temperature sensor -1- .
2. 12.2 Lock locking element -Arrow- .
3. 12.3 Install sheetmetal holder -2- .
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Connecting cable plug for temperature sensor
Connect cable plug for reverse gear switch to the transmission.
1. 13.1 Connect cable plug for reverse gear switch -1- .
2. 13.2 Clip in retaining clip -2- .
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Securing cable plug for reverse gear switch
Connect cable plug for disc valve and neutral gear sensor.
1. 14.1 Connect cable plug for neutral gear sensor -1- .
2. 14.2 Connect cable plug for disc valve -2- .
3. 14.3 Clip in retaining clip -3- .
4. 14.4 Install sheetmetal holder -4- .
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Position of cable plugs and brackets
Secure shift and selector cables -3- on the transmission.
1. 15.1 Install shift and selector cables -3- on the support -2- .
2. 15.2 Install ball joints -1- on exterior shift mechanism.
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Shift and selector cable on transmission
Install drive shafts on the transmission side.
1. 16.1 Fit and tighten new screws -Arrows- between the drive shaft and transmission flange on the plates -1- .
  Counter at the wheel. Get another person to help if necessary!
  
  > Initial tightening 40 Nm (29.5 ftlb.)
  
  > Final tightening torque angle + 110°
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Drive shafts
Additional work for all-wheel drive vehicles:
Install Cardan shaft.

390219 REMOVING AND INSTALLING CARDAN SHAFT
Install diagonal braces.
1. 18.1 Position diagonal struts -A- .
2. 18.2 Fit and tighten screws -1- on the mounting for the longitudinal arm.
  > Tightening torque 55 Nm (40.6 ftlb.)
3. 18.3 Fit and tighten new screws -2- on the body using >9768 - electronic torque wrench, 2 - 100 Nm/1.5 - 74 ftlb. .
  > Initial tightening 70 Nm (51.6 ftlb.)
  
  > Final tightening + 90°
  
  For the Cabriolet: Diagonal brace to outer body
  
  > Tightening torque 30 Nm (22.1 ftlb.)
4. 18.4 Fit and tighten new screws -3- on the rear-axle cross member.
  > Initial tightening 30 Nm (22.1 ftlb.)
  
  > Final tightening + 90°

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Diagonal struts