Removal And Installation: Transmission: Installing

WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Refer to "Transmission, Removing" to get a list of the special tools needed. Refer to REMOVING .

Pay attention to the following list for the subject - "Transmission Fluid, Checking and Filling"

"Checking and Filling Transmission Fluid"
		>>No<<	>>Yes<<	>>Yes<<
Transmission	Original part	X
	no oil outlet	X
	Was completely disassembled		X before installation, see -item 3- LIST ITEM: OIL FILL PLUG transmission fluid capacity, refer to CODES LETTERS, TRANSMISSION ALLOCATION AND CAPACITIES .
	Was partially disassembled (the transmission housing and the clutch housing were not separated from each other)			X after installation, refer to TRANSMISSION FLUID, CHECKING AND FILLING .

-- Clean any locking compound residue from all threaded holes using a tap.

-- Always replace the self locking nuts and bolts.

-- Make sure the alignment pins for centering the engine/transmission are installed inside the cylinder block. Install them if necessary.

If the alignment pins are missing, it will be difficult to shift, there will be clutch problems and the transmission may make noises (loose rattling).

-- Make sure the intermediate plate fits correctly on the engine.

-- Clean the splines on the input shaft and then lubricate them lightly with grease for clutch splines G 000 100.

It must be possible to slide the clutch plate back and forth on the input shaft.

To install the transmission, the 3282 must be equipped with the 3282/39.

-- Align the arms on the 3282 so that they match up with the holes in the 3282/39.

-- Install the mounting elements -A and C- (3282/29) on the 3282/39 as illustrated.

Fig 1: Identifying Transmission Support Adjustment Plate

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the transmission on the V.A.G 1383A.

-- Align the 3282/39 so that it is parallel to the transmission.

-- Install the 3282/29 into the hole in the transmission for the pendulum support bolt.

Fig 2: Aligning Adjustment Plate Parallel To Transmission And Lock Safety Supports On Transmission

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Position the V.A.G 1383A under the vehicle. The -arrow symbol B- on the 3282/39 points in direction of travel.

-- Using the spindles on the 3282, turn the transmission downward in the area of the differential.

-- Push the engine forward slightly with a 2nd technician.

-- Then carefully lift the transmission, when doing so, guide the right flange shaft -A- in the area of the flywheel as shown.

Fig 3: Guiding Right Flange Shaft In Area Of Flywheel/Intermediate Plate

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Using the spindles on the 3282, turn the transmission upward in the area of the differential.

-- Lift the transmission to the engine.

A second technician must continue to press the engine forward.

-- Align the transmission with the engine and install it.

-- Install the lower bolts for attaching the engine to the transmission and tighten them to specification. Refer to TIGHTENING SPECIFICATIONS .

-- After the transmission is attached to the engine, remove the V.A.G 1383A from the transmission.

-- Install the small cover plate, if equipped, behind the right flange shaft -A - -arrows-.

Fig 4: Identifying Cover Plate & Right-Hand Drive Flange

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the upper engine/transmission bolts and tighten them to specification. Refer to TIGHTENING SPECIFICATIONS .

-- Install the transmission mount bracket -A- with new bolts -arrows- to the transmission and tighten them to specification. Refer to TIGHTENING SPECIFICATIONS .

Fig 5: Identifying Transmission Plate Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Use bolt spindles on the 10 - 222 A to align the engine/transmission in the installed position.

Fig 6: Identifying Left Subframe Mount

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install new bolts -arrows- from the left transmission mount and tighten them to specification. Refer to TIGHTENING SPECIFICATIONS .

WARNING:

Only remove the 10 - 222 A when the bolts for the left and right engine/transmission mounts are tightened to specification.

NOTE:

Install the engine/transmission mounts free of tension. Refer to one of the following:

Diesel engines, refer to Specifications

Gas engines, refer to Specifications

-- Install the slave cylinder and tighten the bolts -arrows B- to specification, see -item 15- HYDRAULICS OVERVIEW .

Fig 7: Identifying Transmission Support And Slave Cylinder

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the transmission support and bolts -arrows A- and tighten them to specification. Refer to TIGHTENING SPECIFICATIONS .

-- Install the drive axles to the transmission. Refer to Removal and Installation .

-- Install the drive axle heat shield and bolts -arrows-, if equipped. Refer to DRIVE AXLE HEAT SHIELDS .

Fig 8: Drive Axle Heat Shield Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the pendulum support with new bolts -arrows A, B and C-. Refer to Specifications .

Fig 9: Installing Pendulum Supports With New Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Assemble the exhaust system and then attach it to the subframe. Refer to one of the following:

Diesel engines, refer to Removal and Installation .

Gas engines, refer to Removal and Installation .

-- Install the support -1- and bolt -arrow- to the transmission, if equipped. Tighten the bolt to specification. Refer to Description and Operation , or Description and Operation .

Fig 10: Identifying Exhaust System Brace

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- For transmissions on vehicles with a start/stop system: connect the connector -arrow- to the transmission neutral position sensor -G701-.

Fig 11: Connect The Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the connector -1- to the backup lamp switch -F4-.

Fig 12: Identifying Back-Up Light Switch And Starter Connectors

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the starter, connect the connector -arrow 2- and attach the wire -arrow 3-. Refer to Removal and Installation .

-- Attach the ground cable to the upper engine/transmission bolt.

-- Attach the bracket -B- to the transmission.

Fig 13: Removing/Installing Cable Mounting Bracket At Transmission

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Press the hose/line assembly -A- into the bracket -B- on the transmission.

-- Attach the cable bracket support to the transmission and tighten the bolts -arrows- to specification, see -item 6- LIST ITEM: BOLT.

-- Install the shift lever -A-.

Fig 14: Removing/Installing Metal Relay Lever

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the nut -arrow 4- to specification, see -item 18- LIST ITEM: NUT.

-- Lubricate the pin on the shift lever with a small amount of grease -A-.

-- Attach the shift cable to the shift lever -arrow 1-.

Metal Relay Lever

-- Install the relay lever -B- and secure it with a lock washer -arrow 3-.

-- Apply a small out of grease to the pin on the relay lever -B-.

-- Attach the shift cable to the relay lever -arrow 2-.

Plastic Relay Lever

-- Install the relay lever together with the cable retainer. Refer to PLASTIC RELAY LEVER .

Continuation for All

-- Adjust the shift mechanism. Refer to SHIFT MECHANISM, ADJUSTING .

-- Install the battery tray, the battery cover and the battery. Refer to Removal and Installation .

-- Install the engine cover and the air filter housing. Refer to one of the following:

Gas engines, refer to Description and Operation Description and Operation .

-- Connect the battery and follow the procedure regarding what to do after connecting the battery. Refer to Removal and Installation .

-- Install the lower part of the left front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER .

-- Attach the noise insulation. Refer to Description and Operation .