Section C - Transmission Reinstallation
- Align arms of transmission support according to holes in adjustment plate
- Bolt support elements as illustrated to adjustment plate 3282/42
- Align adjustment plate parallel with transmission
- Secure support element to transmission using bolt -1-
- Screw support element 3282/29 into transmission
- Insert support element -2- into transmission and secure by tightening nut
- Ensure that dowel sleeves are correctly seated in engine block
- Remove plug from the breather opening -1- on the transmission
- Remove plug from the breather opening -2- on the bevel box -2-
- Reinstall cap for breather opening on the bevel box
NOTE:
The old cap can be reinstalled for the breather opening on the bevel box. The new cap for the breather pipe (transmission breather) (012 301 474A) must be installed for the breather opening on the direct shift transmission. This part is included in the repair kit
- Install new cap for the breather pipe (transmission breather) (012 301 474A) for breather openings on the direct shift transmission
- Before installing transmission, check needle bearing in crankshaft
- Raise transmission carefully and move to installation position using transmission support 3282
- Connect transmission to the engine and make sure no wires or hoses get pinched or get caught
- Install M12x65 bolt -5 and tighten to 80 Nm (59 ft. lbs.)
- Install M12x55 bolt -6- and tighten to 80 Nm (59 ft. lbs.)
- Install M10x50 bolt -7- & -8- and tighten to 40 Nm (30 ft. lbs.)
- Install M10x45 bolt -9- and tighten to 40 Nm (30 ft. lbs.)
- Install M 12x70 bolt -10- and tighten to 80 Nm (59 ft. lbs.)
- Remove transmission jack with 3282 support tool
- Reinstall bracket -A- on bevel box with bolts -1- and -2- and hand tighten
- Tighten bolts -1- and -2- in the following sequence:
- Bolt -1- initially to 3 Nm (2 ft. lbs.)
- Bolt -2- to 35 Nm (26 ft. lbs.)
- Bolt -1- to 45 Nm (33 ft. lbs.)
- Lower vehicle and place transmission support -A- between transmission and transmission mounting
- Using new bolts -1- (N 905 970 02) secure transmission support (hand tighten only)
- Pull transmission up to transmission mounting using spindle on support bracket
- Using new bolts -2- (N 102 096 03) secure transmission support to transmission mounting (hand tighten only)
- Tighten bolts -1- to 50 Nm (37 ft. lbs) plus turn an additional 90°
- Tighten bolts -2- to 100 Nm (74 ft. lbs.)
CAUTION:
BEFORE TIGHTENING BOLTS BETWEEN THE TRANSMISSION MOUNTING AND THE TRANSMISSION SUPPORT, THE MOUNTING AND SUPPORT MUST BE ALIGNED IN AN ABSOLUTELY PARALLEL POSITION; OTHERWISE, THE THREADS WILL BE DAMAGED. IF NECESSARY, PUSH THE TRANSMISSION UP AT THE REAR WITH A JACK.
- Reinstall starter and secure in position with upper starter M10x40 bolt with M8 stud and tighten to 40 Nm (29 ft. lbs)
- Raise vehicle on the hoist
CAUTION:
ONLY REMOVE SUPPORT BRACKET 10-222 A AFTER ALL BOLTS FOR THE ASSEMBLY MOUNTING ARE TIGHTENED TO SPECIFIED TORQUE AND THE SUB-FRAME IS INSTALLED.
- Ensure that the drive shaft is reconnected to the bevel box in the previously marked position -arrows-
- Move engine/transmission assembly forward. Bevel box pin must be guided carefully into drive shaft flange when doing this
- When installing drive shaft, do not damage the seals in the flanges. If the seals are damaged, the drive shaft must be replaced
IMPORTANT:
Ensure the drive shaft is horizontal when pushing it onto the guide pin
- Secure drive shaft flexible coupling to the bevel box flange with bolts -arrows- and tighten to 60 Nm (44 ft. lbs.)
- Place sub-frame on VAG 1359/2 and carefully raise
- Move left and right axle shafts into position
- Locate steering gear into correct position on sub-frame
NOTE:
Do not make contact with the side noise insulation and bracket for the power steering hose on the left side when raising
- Secure sub-frame with new bolts -3- (N 907 349 01) and -4- (N 907 528 01) and hand tighten
- Tighten bolt -3- and -4- to 100 Nm (74 ft. lbs.) plus turn an additional 90°
- Install new bolts -1- (N 100 155 06) to secure the steering gear and tighten to 20 Nm (15 ft. lbs.) plus turn an additional 90°
- Install new bolt -2- (N 105 266 02) to secure steering gear and tighten to 20 Nm (15 ft. lbs.) plus turn an additional 90°
- Reposition bracket for vacuum pump and secure with nut over bolt -2-
- At rear of sub-frame, secure bracket for vacuum pump to sub-frame with bolt
- Reinstall reinforcements -3- and secure with bolts -1- and tighten to 35 Nm (26 ft. lbs.)
- Secure right and left couplings to the stabilizer bar using new nut -arrow- (N 015 081 4) and tighten to 90 Nm (66 ft. lbs.)
- Remove strap tool T10038 holding tie rods and steering gear box
- Reinstall pendulum and secure with new bolt -B- (N 905 970 01) and new bolt -C- (N 102 466 05)
- Tighten new bolts -B- and -C- to 50 Nm (37 ft. lbs)
- Secure pendulum to sub-frame with new bolts -A- (N 102 683 02) and tighten to 25 Nm (18 ft. lbs.)
- Secure right axle to flange on the bevel box and left axle to the flange on the transmission and tighten bolts first to 10 Nm (7 ft. lbs.) then final torque all bolts to 70 Nm (52 ft. lbs.)
- Reinstall heat shield over right axle shaft and secure with allen nuts and tighten to 25 Nm (18 ft. lbs.)
- Reposition clamp to connect exhaust pipes and tighten nuts on clamps to 40 Nm (30 ft. lbs.)
- Remove hook tool 3004
- Reinstall ball joint use a new nut -arrow- (N 908 088 01) and tighten to 75 Nm (55 ft. lbs.)
- Reinstall protective plate on bottom of transmission and tighten Torx bolts to 45 Nm (33 ft. lbs.)
- Reinstall M12x55 bolt -1- with M8 stud and tighten to 80 Nm (59 ft. lbs.)
- Secure battery cable to bolt -1- with nut -2- and tighten to 20 Nm (15 ft. lbs.)
- Reposition harness holder bracket and reinstall lower starter M10x45 bolt and tighten to 40 Nm (29 ft. lbs)
- Reposition power steering pressure bracket and secure with bolt
- Reconnect air filter to secondary air pump
- Secure air filter bracket -A- with nuts -1-
- Reinstall coolant hose bracket
- Reinstall left side sound insulation panel
- If removed, reinstall automatic headlight control sensor -1-, secure with nuts -2- and tighten to 10 Nm (7 ft. lbs.)
- Reconnect connector -9- to sensor
- Secure linkage arm bracket -7- to lower control arm using bolt -6- and tighten to 20 Nm (15 ft. lbs.)
- Reinstall center sound insulation panel
- Reinstall wheels and tighten wheel lug bolts diagonally to 50 Nm (37 ft. lbs.)
- Lower vehicle and torque wheel lug bolts diagonally to 120 Nm (89 ft. lbs.)
- Remove engine/transmission support bracket 10-222 A
- Reinstall top center engine/ transmission securing M12x55 bolt -1- and tighten to 80 Nm (59 ft. lbs.)
- Reconnect hoses to transmission oil cooler and remove 3094 clamps
- Using new Torx bolts (N 909 861 01) secure selector cable bracket to the transmission and tighten bolts to 20 Nm (15 ft. lbs.) plus turn an additional 90°
- Carefully press selector lever cable onto selector shaft lever on transmission in opposite direction of arrow
- Install circlip -A- and press downward to secure
NOTE: Do not kink selector lever cable
- Reinstall wire guide and insert connector -1-
- Reconnect connector eyelet -2- and secure with nut
- Reconnect electrical connectors -3- and -4-
- Reinstall carrier for fuse box and secure with bolts
- Clip the fuse box to the carrier lid and close clips
- Clip protective cover for wire harness into position
- Reinstall air cleaner with MAF and hose and secure with screws -1- and -4-
- Reconnect electrical connector -3-
- Reposition clamp -2-
- Reinstall left and right side lock carrier covers
- Reinstall fuse box cover
- Reconnect the negative (-) battery cable to the battery and tighten nut to 6 Nm (53 in. lbs.)
- Reposition luggage compartment floor covering
- Perform battery restoration procedure
- Check transmission oil level and add as required
- Check gear selector cable adjustment and adjust as required
- Check coolant level and add, if necessary
- Use electronic wheel alignment machine V.A.G. 1813 to check/adjust wheel alignment
- Destroy and properly dispose of removed parts