Transmission, Installing, Vehicles With Gasoline Engine And Fwd

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

NOTE:

Refer to "Transmission, Removing" to get a list of the special tools needed. Refer to TRANSMISSION, REMOVING, VEHICLES WITH GASOLINE ENGINE AND FWD .

Replace self-locking bolts and nuts after removing them.

Replace the 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 the input shaft splines and (on used clutch plates) the hub splines. 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 fluid 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-.

Fig 1: Identifying Intermediate Plate Alignment Bushings

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-- 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.

Fig 2: Identifying Adjustment Plate Installed Onto Transmission Support

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-- Align the arms of the Transmission Support so that they align with the holes in the Adjustment Plate.

-- Install the Support Elements -A- as illustrated on the Adjustment Plate.

-- Install the : 3282/29 instead of the Mounting Element -C-.

-- Place the transmission on the : VAS6931 .

-- Align the Adjusting Plate and transmission so that they are parallel to each other.

-- Install the : 3282/29 into the rear hole for the pendulum support bolt on the transmission.

Fig 3: Identifying Engine/Transmission Connecting Bolt

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-- Secure the : VW771/40 in the threaded hole of the transmission housing as illustrated.

-- Secure the transmission on the : 3282 using an M10 X 20 bolt -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 the direction of travel.

NOTE:

Pay attention to all of the lines when installing the transmission.

-- Now turn the transmission in the direction of -arrow- near the differential via the spindles on the : 3282 .

Fig 4: Identifying Spindles Of Transmission Support 3282 Used To Adjust Transmission

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-- Lift the transmission carefully.

-- If necessary, move the transmission into an angled position using the spindles of the : 3282 .

-- Push the engine slightly forward (a second technician is needed).

-- Guide the transmission with the differential -arrow 2- over the subframe.

Fig 5: Identifying Longitudinal Member -Arrow 1- And Subframe -Arrow 2-

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-- Pay attention to the longitudinal member -arrow 1-.

Then the right flange shaft -1- must be guided past the flywheel and past the intermediate plate opening -arrow-.

Fig 6: Guiding Right Flange Shaft Past Flywheel And Opening In Intermediate Plate
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-- Then turn the transmission into its installation position using the spindles from the : 3282 .

-- Align the transmission to the engine (alignment sleeves) and insert it.

CAUTION:

Brake fluid can escape from the bleeder on the transmission.

-- Install the engine/transmission connecting bolts -1 to 3- and tighten them. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

Fig 7: Identifying Lower Connecting Bolts For Engine/Transmission

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-- After transmission is bolted to the bottom of the engine, remove the : 3282 from the 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 Figure and tighten the nut. Refer to OVERVIEW - SHIFT MECHANISM .

-- Install the relay lever together with the cable retainer. Refer to Figure.

-- Install transmission bracket -1- with new bolts -arrows-. Refer to OVERVIEW - ASSEMBLY MOUNTS .

Fig 8: Identifying Transmission Bracket (1) Bolts

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CAUTION:

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.

Fig 9: Aligning Engine/Transmission In Installed Location

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-- Install new bolts -arrows- and tighten. Refer to OVERVIEW - ASSEMBLY MOUNTS .

NOTE:

Install the engine/transmission mount free of tension. Refer to ASSEMBLY MOUNT, ADJUSTING .

-- If present, connect ground cable -arrow-.

Fig 10: Identifying Nut

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CAUTION:

Risk of accident!

Only remove the : 10-222A if all of the bolts for the assembly mount are tightened to the tightening specification.

-- Connect hose/line assembly with bleeder. Refer to the figure below.

Fig 11: Disconnect and Connect Clutch Mechanism Wires

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Fig 12: Identifying Hose Clamps 3094, Clamp Supply Hose And Master Cylinder

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-- 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. If necessary, install the vacuum hose. Refer to BRAKE BOOSTER/BRAKE MASTER CYLINDER .

-- Mount the cable bracket on the transmission and tighten the bolts and nuts -arrows-. Refer to OVERVIEW - SHIFT MECHANISM .

Fig 13: Identifying Transmission Cable Bracket Bolts

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-- Install the selector cable in the cable retainer.

Fig 14: Identifying Lock Washer -1- And Pin -Arrow- On Transmission Shift Lever -2-

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-- Apply a small amount of grease on the pin -arrow- for the selector lever -2-.

Refer to the Parts Information for the grease allocation.

-- Replace the lock washer -1- each time it is removed.

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

-- Install the starter. Refer to STARTER, REMOVING AND INSTALLING .

-- Connect the front left connectors to the transmission:

Fig 15: Identifying Park/Neutral Position Switch

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Transmission for vehicles with start/stop system: Transmission Neutral Position Sensor -G701-
Back-Up Lamp Switch -F4-

-- Install the fan shroud with the radiator fan -arrow-. Refer to FAN SHROUD, REMOVING AND INSTALLING .

Fig 16: Fan Shroud

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-- Install the charge air hose -1-. Refer to OVERVIEW - CHARGE AIR SYSTEM .

Fig 17: Identifying Hose And Clamps

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-- Assemble the exhaust system. Refer to OVERVIEW - MUFFLER .

-- Install pendulum support with new bolts. Refer to PENDULUM SUPPORT, REMOVING AND INSTALLING .

Fig 18: Identifying Pendulum Support

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NOTE:

Threaded inserts (for example, "Heli Coil") are found in the pendulum support fastening holes on some transmissions. Refer to Figure.

For Front Axle Differential Lock

Fig 19: Locating Axle Differential Lock Control Module Connector

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-- Install the connector -arrow- on the Differential Locks Control Module -J647-.

Continuation for All

-- Install the drive axles. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Assemble the lower control arm. Refer to OVERVIEW - LOWER CONTROL ARM AND BALL JOINT .

-- Install the drive axle heat shield (if equipped). Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

Fig 20: Drive Axle Heat Shield

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-- If removed, install the Left Front Level Control System Sensor -G78- on the lower control arm. Refer to LEFT FRONT LEVEL CONTROL SYSTEM SENSOR -G78- /RIGHT FRONT LEVEL CONTROL SENSOR -G289-, REMOVING AND INSTALLING .

Fig 21: Identifying Left Front Level Control System Sensor

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-- Connect the connector -1- to the Oil Level Thermal Sensor -G266-.

Fig 22: Disconnecting Connector From Oil Level Thermal Sensor G266

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-- 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 .

-- Install the battery tray, battery and the battery cover. Refer to BATTERY, REMOVING AND INSTALLING .

-- Install the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Install the engine cover. Refer to ENGINE COVER, 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 .