Transmission, Installing
Transmission, Installing
Install in reverse order, paying attention to the following:
• When performing repairs, replace self-locking nuts and bolts.
• Always replace bolts that are secured with additional torque as well as sealing rings, seals, and O-rings.
• All cable ties that are opened or cut open during removal must be replaced in the same positions during installation.
• Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of lubricant (G 000 100) on splines. Then move clutch plate back and forth on input shaft until the hub moves freely on the shaft. Excess grease must be removed.
• If the transmission is replaced, modify the transmission shift lever and selector relay lever.
- All threaded bores, in which self-locking bolts are threaded, must be cleaned of locking fluid residue using a thread tap.
- If there are no alignment sleeves for centering the engine and transmission in the cylinder block, insert them.
- Make sure that intermediate plate is engaged on sealing flange and has been slid on to alignment sleeves - arrows -.
- Check the centralization of the clutch plate. Refer to => [ LuK Clutch ] LuK Clutch.
- Check the release bearing for wear. Replace the clutch slave cylinder with the release bearing if necessary. Refer to => [ Clutch Release Mechanism, Clutch Slave Cylinder Assembly Overview ] Clutch Release Mechanism, Clutch Slave Cylinder Assembly Overview.
- Carefully raise transmission with (3282).
- Align transmission to engine and install.
- Guide the transmission past drive axle - A - and front exhaust pipe - B - with output flange - C -. Rotate the output flange if necessary.
• Pay attention to electromechanical steering gear when installing the transmission.
• Pay attention to all lines when installing transmission.
- If applicable, insert bevel box bracket - A -.
- Insert and tighten lower engine/transmission connecting bolts - 1-3 -, then tighten all remaining connecting bolts.
- Lubricate the bearing areas and sliding surfaces of selector relay lever - 1 - with grease (G 000 450 02).
Metal selector relay lever
- Insert selector relay lever - 1 - and secure with the lock washer - arrow -.
Plastic selector relay lever - 1 -
- Insert the selector relay lever with catch => [ Remove the Selector Relay Lever
with Catch from the Transmission Shift Lever and
Attach ] Shift Cable and Selector Cable From Model Year 2008 Assembly Overview
- Insert the selector relay lever with clip => [ Remove the Selector Relay Lever from the Transmission Shift Lever and
Attach ] Shift Cable and Selector Cable From Model Year 2008 Assembly Overview
All Vehicles
- Install the transmission bracket - arrows -. Refer to => [ Subframe Mount Assembly Overview ] Description and Operation.
- Align engine/transmission in installed position. To do this, tighten (10 - 222 A) spindles until transmission bracket - 1 - lies on transmission mount - 2 -.
- Also place the (V.A.G 1383 A) under the transmission in the area of the differential and raise until the transmission bracket is parallel to the transmission mount.
• To prevent the threads in the transmission bracket from being damaged, the transmission mount and bracket must be parallel to one another.
- Install the transmission mount. Refer to => [ Subframe Mount Assembly Overview ] Description and Operation.
• Install engine/transmission mountings stress-free.
Do not remove (10 - 222 A) until all bolts for left assembly mounting have been tightened to tightening specification.
- Install the bevel box bracket.
- If equipped, install small cover plate - A - behind the bevel box - arrow -.
- Install the left and right drive axles.
- Install the right drive axle heat shield.
- Press the engine/transmission assembly to the bulkhead while carefully guiding the bevel box pin into the flange/driveshaft.
• Seal in driveshaft flange must not be damaged when removing and installing transmission. Replace driveshaft if damaged.
• Slip the driveshaft horizontally onto the centering pin.
- Secure the driveshaft with the flexible disk on the bevel box flange - arrows -.
:
- Installing the subframe.
- Install pendulum support. Refer to => [ Subframe Mount Assembly Overview ] Description and Operation.
• The holes for the pendulum support on transmissions from 05.28.07 have threaded inserts (for example HeliCoil).
• How to recognize: collar on the first thread - arrow -.
• Note the correct mounting bolts and tightening specifications - 2 - => [ Bolts ] Description and Operation.
- Installing the steering gear on the subframe.
- Install the exhaust system and cross member.
- Install the fan shroud.
- Install starter.
- Install the hose/line assembly or plastic line. Refer to => [ Hose/Line Assembly or Plastic Line ] Service and Repair.
- Bleed the clutch system. Refer to => [ Clutch System, Bleeding ] Clutch System, Bleeding.
- Install the control cable mounting bracket on the transmission. Refer to => [ Shift Cable and Selector Cable to Model Year 2007 Assembly Overview ] Shift Cable and Selector Cable to Model Year 2007 Assembly Overview.
- Apply a small amount of grease (G 000 450 02) to the transmission shift lever - 1 - pins - arrow -.
- Slide the shift cable onto the pin - arrow - and secure with lock washer - 3 -.
Metal selector relay lever - 2 -
- Apply a small amount of grease (G 000 450 02) to the pin - arrow - of selector relay lever - 2 -.
- Slide the selector cable onto the pin - arrow - and secure with the lock washer - 4 -.
Plastic selector relay lever - 2 -
- Insert the selector cable in the control cable retainer.
Continued for all vehicles
- Adjust shift mechanism. Refer to => [ Shift Mechanism, Adjusting ] Adjustments.
- Install the air filter housing.
- Connect battery. Heed the instructions for work to be performed following battery connection.
- Check transmission fluid level inside the manual transmission. Refer to => [ Manual Transmission, Checking Gear Oil Level ] Manual Transmission, Checking Gear Oil Level.
- Axle oil level in bevel box, checking. Refer to => [ Gear Oil in Bevel Box, Checking ] Gear Oil In Bevel Box, Checking.
- Install the left and right noise insulation - arrows -.
- Install the noise insulation frame.
- Install the noise insulation.
- Install the wheels.
Transmission Installation Tightening Specifications
• The tightening specifications apply only to lightly greased, oiled, phosphated, or black-finished nuts and bolts.
• Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant.
• Do not use degreased parts.
• Tolerance for torque specification ± 15%.
Manual Transmission Mount on Engine
Additional specification
Bevel box bracket - A - tightening specification and sequence
Right Drive Axle Heat Shield Tightening Specification
- Tighten bolts - arrows - to 25 Nm.