Volkswagen Workshop Service and Repair Manuals

Installing   Note

t  Before installing gearbox press clutch release lever towards gearbox housing and secure with assembly pin, assembly bolt or M8 x 35 bolt. Remove after gearbox has been installed. The hole will then be sealed by the 3rd cable support bracket securing bolt or plugged.

t  When replacing gearbox, the senders for speedometer (Fig.), gear selector and relay lever must be transferred to new assembly. –  Clean input shaft splines and lightly grease with grease -G 000 100-. The clutch plate must slide easily to and fro on the input shaft. –  Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary. –  Ensure that intermediate plate, if present, is correctly seated on engine.

–  Bolt support rail -T10036- to both pendulum support securing holes on subframe -arrows-. –  Fit engine support -3300 A- so that it almost touches subframe and bolt on -arrows-. –  Press engine forward carefully.   Note Observe power assisted steering line. To install gearbox 02C with bevel box, set up gearbox support -3282- with adjustment plate -3282/18-. –  Align arms of gearbox support according to holes in adjustment plate.

–  Screw in support elements -A- as illustrated on adjustment plate. Arrow symbol -B- on adjustment plate points in vehicle driving direction. –  Place gearbox on gearbox jack. –  Align adjustment plate and gearbox parallel to each other and lock safety support on gearbox.

–  Place gearbox jack under vehicle. –  Rotate gearbox to left using spindles of gearbox support -3282-.

–  Then raise gearbox carefully and guide past subframe -arrow-.

–  Then guide the gearbox with bevel box -A- carefully past support device for engine -3300 A-. –  Now swing gearbox to rear and bring to installation position using gearbox mounting -3282-. –  Insert gearbox.   Note Observe power assisted steering line. –  Then install starter and secure with lower bolt → Rep. Gr.27. –  Fit bracket for power assisted steering line to starter and gearbox. –  Screw in lower engine/gearbox securing bolts and tighten to specified torque → Chapter.

–  Remove engine support -3300 A--arrows-. –  Then remove bolts -A- and remove support rail -T10036-.

–  Install rear engine/gearbox connecting bolt -arrow A- and tighten to specified torque → Chapter. –  Install bevel box bolt -arrow B- → Chapter. –  Screw in upper engine/gearbox securing bolts and tighten to specified torque → Chapter.

–  Install gearbox bracket -A- using new bolts -arrows- and tighten to specified torque → Chapter. –  Align engine and gearbox in installation position.

–  Now install hexagon bolts -arrows- for engine mounting in right assembly mounting → Engine; Rep. Gr.10. –  Secure power steering oil reservoir above right-hand assembly mounting.

–  Install new hexagon bolts -arrows B- for left assembly mounting in gearbox mounting and tighten to specified torque → Chapter. –  Then install gearbox support -arrow A- on gearbox and tighten to specified torque → Chapter.   WARNING Do not remove support bracket -10 - 222 A- until the bolts securing the left gearbox bracket have been tightened to specified torque.

–  If small cover plate -A- for flywheel was removed from behind bevel box, install it -arrows-. –  Install lower flywheel cover plate, if part of original equipment.

–  Bolt bevel box carrier to engine and bevel box -arrows- → Anchor.

–  Bolt turbocharger oil return line to engine -arrow- → Rep. Gr.21. –  Press engine/gearbox assembly towards bulkhead panel, carefully guiding bevel box pin into propshaft flange.   Note

t  When removing and installing gearbox, do not damage seal in the propshaft flange. t  Renew propshaft if damaged. t  Ensure that propshaft is horizontal when pushing onto centring pin.

–  Bolt propshaft with flexible coupling to bevel box flange -arrows- and tighten to specified torque → Item.

–  Install pendulum support -arrows A and B- → Running gear, axles, steering; Rep. Gr.40. –  Use new bolts for securing. –  Attach drive shafts to gearbox → Running gear, axles, steering - front and four-wheel drive; Rep. Gr.40. –  Reconnect exhaust system → Rep. Gr.26.

–  Install slave cylinder and tighten bolts to specified torque → Item.

–  Install selector cable support bracket on gearbox and tighten bolts -arrows- to specified torque → Item. If necessary push in hose line on selector cable support bracket.

–  Fit gear selector cable -B- with gearbox selector lever -arrow-. –  Tighten hexagon nut -arrow- to specified torque → Item. –  Fit gate selector cable -A- with relay lever and secure -arrow-.

–  Attach connector for reversing light -arrow 2-. Attach all other electrical connections and earth wires to gearbox and to the engine/gearbox securing bolts. –  Attach connector to speedometer sender -arrow 1-.

–  Install complete air filter housing (bolts -4- and -5-) and then push intake hose -1-, connector -2- and hose -3- onto air mass meter → Rep. Gr.24. –  Connect earth strap to battery.   Note Note radio code for vehicles with coded radio. –  Checking gear oil in manual gearbox with bevel box → Chapter. Gear oil specification → Chapter –  Adjust selector mechanism → Chapter. –  Install engine cover. –  Install noise insulation, if fitted.