Volkswagen Workshop Service and Repair Manuals

Installing gearbox   Note Refer to procedure „Removing gearbox“ for required special tools → Chapter. Observe the following table on the subject of „checking and topping up gear oil“.

„Checking and topping up gear oil“
		»No«	»Yes«	»Yes«
Gearbox	Original part	X
	No oil loss	X
	Completely dismantled		X Before installation → Item Oil capacity → Chapter
	Partially dismantled l  (Gearbox housing and clutch housing were not separated.)			X After installation → Chapter

–  All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap. –  Always renew self-locking bolts and nuts. –  Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary. If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur. –  Ensure that intermediate plate is correctly seated on engine. –  Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100-. The clutch plate must slide easily to and fro on the input shaft. To install gearbox „02S“, set up gearbox support -3282- with adjustment plate -3282/39-. –  Align arms of gearbox support according to holes in adjustment plate.

–  Screw in support elements-A - and -C- (pin -3282/29-) on adjustment plate as shown. –  Place gearbox on engine and gearbox jack. –  Align adjustment plate and gearbox parallel to one another.

–  Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support. –  Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel. –  Using spindles of gearbox support -3282-, tilt gearbox downwards in vicinity of differential.

–  Then carefully raise gearbox, guiding with right flange shaft -A- past flywheel and intermediate plate as shown. –  Using spindles of gearbox support -3282-, tilt gearbox upwards in vicinity of differential. –  Raise gearbox to engine. –  Have a second mechanic push engine forwards slightly. –  Align gearbox to engine and join. –  Screw in lower engine/gearbox securing bolts and tighten to specified torque → Chapter. –  After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.

–  If small cover plate -A- had been installed behind the right flange shaft -arrows-, install it. –  Screw in upper engine/gearbox securing bolts and tighten to specified torque → Chapter.

–  Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque → Chapter.

–  Align engine and gearbox in installation position using both spindles of support bracket -10-222A-. –  Install new bolts -arrows- for left assembly mounting in gearbox mounting and tighten to specified torque → Chapter.   WARNING Do not remove support bar -10-222 A- until all bolts securing the left and right assembly mountings have been tightened to specified torque.   Note Install engine and gearbox mounting free of tension → Rep. gr.10.

–  Install slave cylinder and tighten bolts -arrows B- to specified torque → Item. –  Then install gearbox support with new bolts -arrow A- and tighten to specified torque → Chapter. –  Attach drive shafts to gearbox → Running gear, axles, steering; Rep. gr.40.

–  Install drive shaft heat shield, if present -arrows- → Running gear, axles, steering; Rep. gr.40.

–  Install pendulum support with new bolts -arrows A-, -B- and -C- → Running gear, axles, steering; Rep. gr.40. –  Assemble exhaust system and attach exhaust system bracket to subframe → Rep. gr.26.

–  If present, bolt exhaust system strut -1- to gearbox and tighten bolt -arrow- to specified torque → Rep. gr.26.

–  Push connector -1- onto reversing light switch -F4-. –  Install starter, push on connector -arrow 2- and bolt on wire -arrow 3- → Electrical system; Rep. gr.27. –  Install earth strap at upper engine/gearbox connecting bolt. –  Check for correct installation position of vacuum hose for brake system, install vacuum hose if necessary → Rep. gr.47.

–  Attach support -B- to gearbox. –  Press pipe/hose line -A- into retainer -B- on gearbox. –  Install cable support bracket on gearbox and tighten bolts -arrows- to specified torque → Item.

–  Install gearbox selector lever -A- → Fig.. –  Tighten hexagon nut -arrow 4- to specified torque → Item. –  Spread a small amount of grease on pin of gearbox selector lever -A-. Allocate grease using → Electronic parts catalogue (ETKA). –  Connect gear selector cable to gearbox selector lever -arrow 1-. Metal relay lever –  Install relay lever -B- and secure with securing clip -arrow 3-. –  Spread a small amount of grease on pin of relay lever -B-. Allocate grease using → Electronic parts catalogue (ETKA). –  Connect gate selector cable to relay lever -arrow 2-. Plastic relay lever –  Install relay lever together with cable end-piece → Chapter. Continuation for all –  Adjust selector mechanism → Chapter. –  Install battery tray, battery and battery cover → Electrical system; Rep. gr.27. –  Install engine cover → Rep. gr.23 or air filter → Rep. gr.24. –  Set foam pieces on upper edge of left and right wings → Body, front; Rep. gr.50. –  Reconnect battery and perform work required after connecting battery → Electrical system; Rep. gr.27. –  Install lower part of front left wheel housing liner → General body repairs, exterior; Rep. gr.66. –  Install noise insulation → General body repairs, exterior; Rep. gr.50.