Transmission, Installing, Vehicles With Turbo Diesel Engine
Refer to "Transmission, Removing" to get a list of the special tools needed. Refer to TRANSMISSION, REMOVING, DIESEL VEHICLES .
Replace self-locking bolts and nuts after removing them.
Replace bolts that were tightened with an additional turn after removing them.
Reinstall all cable ties that were loosened or cut off during removal at the same locations during installation.
Clean input shaft splines and the hub splines on a used clutch plate. Remove any corrosion and apply a very thin coating of Grease for Clutch Plate Shaft Splines on the splines. Then move the clutch plate back and forth on the input shaft until the hub moves freely on the shaft. Excess grease must be removed.
-- If the transmission is replaced, replace the gearshift lever and the relay lever.
-- Use a thread cutter to carefully clean all threaded holes containing self-locking bolts to remove any locking compound residue.
-- The alignment sleeves for centering the engine/transmission must be present inside the cylinder block. Install them if they are missing.
If the alignment sleeves are missing, it will be difficult to shift, there will be clutch problems and the transmission may make noises (loose rattling).
Engage the intermediate plate on the sealing flange and push it onto the alignment sleeves -arrows-.
-- Check the release bearing for wear. Replace the clutch slave cylinder with release bearing if necessary. Refer to CLUTCH SLAVE CYLINDER WITH RELEASE BEARING, REMOVING AND INSTALLING .
The :3282 is equipped with the :3282/33 to install the transmission.
-- Align the arms of the Transmission Support so that they match up with the holes in the Adjustment Plate.
-- Install the Support Elements -A- as illustrated on the Adjustment Plate.
-- Install the Mounting Element -C- instead of the :3282/29 .
-- Place the transmission on the :VAS6931 .
-- Align the Adjustment Plate so that it is parallel to the transmission.
-- Install the :3282/29 into the rear hole for the pendulum support bolt on the transmission.
-- Secure the :VW771/40 inside the threaded hole in the transmission housing as illustrated.
-- Secure the transmission on the :3282 using the bolt (M10 X 20) -A-.
The drift -B- must be flush at the bottom with the guide on the :3282 -arrow-.
-- Position the :VAS6931 under the vehicle. The arrow on the adjusting plate points in direction of travel.
Pay attention to all of the lines when installing the transmission.
-- Lift the transmission carefully.
-- Turn the transmission into it installed position using the spindles on the :3282 .
-- Align the transmission to the engine (alignment sleeves) and insert it.
- Brake fluid can escape from the bleeder on the transmission.
-- Install the engine/transmission connecting bolt -C- (→ illustration above) and tighten. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .
-- Install engine/transmission connecting bolt -arrow- and tighten. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .
-- Install all lower engine/transmission connecting bolts and tighten. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .
-- After transmission is bolted to engine at bottom, remove the :3282 from transmission.
-- Install all upper engine/transmission connecting bolts and tighten. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .
-- Attach the gearshift lever to the transmission gearshift shaft. Refer to Installing the Transmission Shift Lever and tighten the nut. Refer to OVERVIEW - SELECTOR MECHANISM .
-- Install the relay lever together with the cable retainer. Refer to Relay Lever with Cable Retainer, Removing and Installing .
-- Install transmission bracket -1- with new bolts -arrows-. Refer to OVERVIEW - ASSEMBLY MOUNTS .
There is a risk of damaging the threads in the transmission bracket by inserting the bolts at an angle.
- The transmission mount and transmission bracket must be parallel to each other in order to prevent the transmission bracket thread from becoming damaged.
-- Tighten the :10-222A spindles until the transmission bracket -1- touches the transmission mount -2- to align the engine/transmission assembly in its installed position.
-- Install new bolts -arrows- and tighten. Refer to OVERVIEW - ASSEMBLY MOUNTS .
Install the engine/transmission mount free of tension. Refer to SUBFRAME MOUNT, ADJUSTING .
-- If present, connect ground cable -arrow-.
Risk of accident!
- Only remove :10-222A when all subframe mount bolts are tightened to the tightening specification.
-- Connect hose/line assembly with bleeder. Refer to graphic below.
-- After removing the :3094 , the hose must be formed back into its original shape.
-- Bleed the clutch system. Refer to CLUTCH MECHANISM, BLEEDING .
-- Make sure the vacuum hose for the brake system is installed correctly. Install a vacuum hose, if necessary. Refer to OVERVIEW - BRAKE BOOSTER/BRAKE MASTER CYLINDER .
-- Mount the cable bracket on the transmission and tighten the bolts and nuts -arrows-. Refer to OVERVIEW - SELECTOR MECHANISM .
-- Install the selector cable in the cable retainer.
-- Apply a small amount of grease on the pin -arrow- for the gearshift lever -2-.
-- Replace the lock washer -1- each time it is removed.
-- Adjust the gearshift mechanism. Refer to SELECTOR MECHANISM, ADJUSTING .
-- Install the starter. Refer to STARTER, REMOVING AND INSTALLING .
-- Connect the front left connectors to the transmission:
- Transmission for vehicles with start/stop system: Transmission Neutral Position Sensor -G701-
- Back-Up Lamp Switch -F4-
-- Install the drive axles. Refer to DRIVE AXLE, REMOVING AND INSTALLING .
-- Install the drive axle heat shield (if equipped). Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .
-- Assemble the exhaust system. Refer to OVERVIEW - MUFFLER [FOR ENGINE(S) CRUA] and OVERVIEW - MUFFLER [FOR ENGINE(S) CNSB, CNSA, CXBB, CXBA, CXCB, CXCA] .
-- Install the subframe together with pendulum support. Refer to PENDULUM SUPPORT, REMOVING AND INSTALLING .
Threaded inserts (for example, "Heli Coil") are found in the pendulum support fastening holes on some transmissions. Refer to Transmission with Threaded Insert (for example Heli Coil) for Attaching the Pendulum Support .
For Front Axle Differential Lock
-- Install the connector -arrow- on the Differential Locks Control Module -J647-.
Continuation For All
-- Install pendulum support with new bolts. Refer to PENDULUM SUPPORT, REMOVING AND INSTALLING .
-- Connect the connector -1- to the Oil Level Thermal Sensor -G266-.
-- Check the transmission fluid level in the manual transmission. Refer to TRANSMISSION FLUID LEVEL, CHECKING .
-- Check oil level for the front axle differential lock. Refer to FRONT AXLE DIFFERENTIAL LOCK FLUID LEVEL, CHECKING .
-- If unclipped, carefully clip in the A/C system pipe and do not disconnect the line system. Refer to SYSTEM OVERVIEW - REFRIGERANT CIRCUIT - R1234yf and SYSTEM OVERVIEW - REFRIGERANT CIRCUIT .
-- Install fuel filter. Do not open the line system. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING [FOR ENGINE(S) CNSB, CNSA, CXBB, CXBA, CXCB, CXCA] and FUEL FILTER, REMOVING AND INSTALLING [FOR ENGINE(S) CRUA] .
-- Install the battery tray, battery and the battery cover. Refer to BATTERY TRAY, REMOVING AND INSTALLING and BATTERY, REMOVING AND INSTALLING .
-- Install the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING [FOR ENGINE(S) CNSB, CNSA, CXBB, CXBA, CXCB, CXCA] and/or AIR FILTER HOUSING, REMOVING AND INSTALLING [FOR ENGINE(S) CRUA] .
-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING [FOR ENGINE(S) CNSB, CNSA, CXBB, CXBA, CXCB, CXCA] and ENGINE COVER, REMOVING AND INSTALLING [FOR ENGINE(S) CRUA] .
-- Install the plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .
-- Install the windshield wiper arms. Refer to WINDSHIELD WIPER ARM, REMOVING AND INSTALLING .
-- Install the lower section of the left front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .
-- Install the noise insulation. Refer to OVERVIEW - NOISE INSULATION .