Modifying support rails VW 457/1: Installing

WARNING: This page is about a different variant/trim than selected.

NOTE:

Fig 1: Securing Clutch Release Lever With Bolt

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Before installing the transmission press the clutch release lever toward the transmission housing and secure it with an assembly pin, assembly bolt or a M 8 x 35 bolt. Remove it after the transmission has been installed. The hole will then be sealed by the 3rd cable support bracket securing bolt or plugged.

Fig 2: Identifying Sensor For Speedometer

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When replacing a transmission, the sensors for the speedometer (See Fig 2 ), gear selector and relay lever must be transferred to the new assembly.

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

The clutch plate must be able to slide lightly back and forth on the input shaft.

Check whether dowel sleeves for aligning engine/transmission are fitted in cylinder block, install if necessary.
Ensure that intermediate plate is correctly positioned on engine.

Fig 3: Identifying Support 3300 A, Support Rail VW 457/1 & Hex Bolts

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Bolt support rail VW 457/1 to both pendulum support securing holes on subframe.
Insert spacers totaling 6 mm between subframe and support rail VW 457/1.

-A- Qty. 2 hex bolts M 8 x 25

Fit support 3300 A and secure (arrows).

Fig 4: Identifying Support 3300 A

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Vehicles with 5 valve engine

The support 3300 A must sit on the threaded boss on the engine.

Continued for all vehicles

Press engine forward carefully.

NOTE: Do not damage power steering line.

Assemble transmission jack with transmission support 3282, adjustment plate 3282/8 for "02A" transmission and support elements as follows:
Place adjustment plate 3282/8 on transmission support 3282. (Adjustment plate only fits in one position).
Align arms of transmission support according to holes in adjustment plate.

Fig 5: Identifying Support Elements & Symbol On Adjustment Plate

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Bolt on support elements -A-, as illustrated, on adjustment plate.
Place transmission on transmission jack.
Align adjustment plate and transmission parallel with one another and lock safety supports on transmission.

Fig 6: Transmission Jack Positioned Under Vehicle

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Place transmission jack under vehicle, arrow symbol -B- (Refer to Fig 5 ) on adjustment plate points to front of vehicle.
Incline transmission to left via spindles of transmission mounting 3282.
Insert transmission.

NOTE: Do not damage power steering line.

Install lower engine/transmission securing bolts.

Fig 7: Identifying Support 3300 A, Support Rail VW 457/1 & Hex Bolts

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Remove support 3300 A (arrows).
Remove bolts -A- and remove support rail VW 457/1.
Install upper engine/transmission securing bolts.

Fig 8: Identifying Transmission Mount

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Install transmission mount -A- with new bolts (arrows).
Align engine/transmission in installation position.

Fig 9: Identifying Transmission Support & Hex Bolts

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Install new hex bolts (arrows -B-) for left hand assembly mounting in transmission mounting.
Mount transmission support (arrows -A-) to transmission.

WARNING:

Do not remove support bar 10-222A until the bolts securing the left-hand transmission mount have been tightened to torque setting.

Fig 10: Identifying Pendulum Support & Engine/Transmission Securing Bolt

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Install lower engine/transmission securing bolt (arrow -A-).
Install pendulum support (arrows). Use new bolts for securing.
Reconnect exhaust system.

Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP, 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH, 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW, 26 EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 2V ENGINE MECHANICAL, FUEL INJECTION & IGNITION, ENGINE CODE(S): AEG, AVH, AZG, BBW, BEV, 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.8 LITER VR6 2V ENGINE MECHANICAL, ENGINE CODE (S): AFP, 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.8 LITER VR6 4V ENGINE MECHANICAL, ENGINE CODE(S): BDF and 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 LITER VR6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BJS

Install retainer for power steering line on starter and on transmission.

Fig 11: Identifying Cover Plate & Right-Hand Drive Flange

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If removed, install small cover plate -A- behind right-hand drive flange (arrows).
If removed, install large cover plate for clutch.
Fit drive shafts to transmission.

Refer to 40 FRONT SUSPENSION

If removed, install protective cap for right-hand inner constant velocity joint to engine.
Install starter.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Fig 12: Identifying Slave Cylinder

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Install slave cylinder.

Fig 13: Cable Support Bracket Bolts

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Install cable support bracket on transmission (arrows), if necessary push hose onto cable support bracket.

Transmissions up to 05.99

Fig 14: Identifying Balance Weight, Gear Selector Cable & Actuating Arm/Relay Lever

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Install gear selector cable -B- and balance weight -A- on gear selector lever.
Lift tab in direction of arrow and fit gate selector cable on follower/relay lever -C-.

Fig 15: Identifying Speedometer Sensor & Reverse Light Connectors (Up To 05.99)

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Attach reverse light connector (arrow -2-). Attach all other electrical connections and ground wires to transmission and to engine/transmission securing bolts.
Attach connector to speedometer sensor (arrow -1-).
Assemble air intake duct.

Refer to 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWD, 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): AWW, AWP, 24 MULTIPORT FUEL INJECTION (MFI) for 2.0 LITER 4-CYL. 2V ENGINE MECHANICAL, FUEL INJECTION & IGNITION, ENGINE CODE(S): AEG, AVH, AZG, BBW, BEV, 24 MULTIPORT FUEL INJECTION (MFI) for 2.8 LITER VR6 2V FUEL INJECTION IGNITION, 24 MULTIPORT FUEL INJECTION (MFI) for 2.8 LITER VR6 4V FUEL INJECTION IGNITION and 24 - MULTIPORT FUEL INJECTION (MFI) for 3.2 LITER VR6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BJS

Reconnect ground strap to battery.

NOTE: Note radio coding for vehicles with coded radio.

Check transmission oil. Refer to Gear oil, checking .
Adjust gear selector mechanism. Refer to Gear selector mechanism up to 05.99, adjusting .
Install engine cover.
Install insulation tray below engine/transmission, if fitted.

Transmission from 05.99

Fig 16: Identifying Gate Selector Cable, Gear Selector Cable & Nut

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Fit gear selector cable -B- with transmission selector lever (arrow).
Fit gate selector cable -A- with relay lever and secure (arrow).

Fig 17: Identifying Vehicle Speed Sensor & Reverse Light Connector (From 05.99)

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Attach reverse light connector (arrow -2-). Attach all other electrical connections and ground wires to transmission and to engine/transmission securing bolts.
Attach connector to speedometer sensor (arrow -1-).
Assemble air intake duct.

Reconnect ground strap to battery.

NOTE: Note radio coding for vehicles with coded radio.

Check transmission oil. Refer to Gear oil, checking .
Adjust gear selector mechanism. Refer to Gear selector mechanism from 05.99, adjusting .
Install engine cover.
Install insulation tray below engine/transmission, if fitted.

Continued for all vehicles