Transmission, Installing, Vehicles With Turbo Diesel Engine
Refer to "Transmission, Removing" to get a list of the required special tools. Refer to TRANSMISSION, REMOVING, VEHICLES WITH DIESEL ENGINE .
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 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 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-.
-- 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 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.
-- Secure the : VW771/40 inside the threaded hole in 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.
Pay attention to all of the lines when installing the transmission.
-- Lift the transmission carefully.
-- 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.
- 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 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 Figure.
-- 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 ASSEMBLY MOUNT, ADJUSTING .
-- If present, connect ground cable -arrow-.
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 Fig 8.
-- 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 Brake Booster/Brake Master Cylinder .
-- Mount the cable bracket on the transmission and tighten the bolts and nuts -arrows-. Refer to OVERVIEW - SHIFT MECHANISM .
-- Install the selector cable in the cable retainer.
-- 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:
- 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 .
-- Install the subframe together with the pendulum support. Refer to OVERVIEW - SUBFRAME .
Threaded inserts (for example, "Heli Coil") are found in the pendulum support fastening holes on some transmissions. Refer to Figure.
-- 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 .
-- 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 fuel filter. Do not open the line system. Refer to OVERVIEW - FUEL FILTER .
-- Install the battery tray, battery and the battery cover. Refer to BATTERY, REMOVING AND INSTALLING .
-- Install the entire air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .
-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .
-- Install the plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .
-- Install the windshield wiper arms. Refer to WINDSHIELD WIPER ARMS, 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 .