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. –  Unbolt right securing bolt for heat shield -1- from subframe. –  Secure retainer -T10346- with bolt -2-. -2- = Flange bolt M6 x 20. –  Secure engine support -3300 A- to bracket -T10346-.

–  Place a cloth between engine support -3300 A- and oil pan. –  Press engine forwards using spindle of engine support -3300 A-.   Note Observe connecting lines, hoses and radiator when moving engine/gearbox assembly. 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.   Note Be careful of all lines when installing gearbox. –  Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel.

l  Then the right flange shaft must be guided past the flywheel -arrow 2- and the notch in the intermediate plate -arrow 1-.

–  Guide left flange shaft -B- past subframe bracket -arrow- as shown. –  Place intermediate plate onto dowel sleeves on engine if necessary. –  Align gearbox to engine and join. –  Screw in lower engine/gearbox securing bolts and starter securing bolt and tighten to specified torque → Chapter. –  After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox. –  Remove engine support -3300 A- and bracket -T10346-.

–  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. To do this, lift until gearbox is fully in contact with left engine/gearbox mounting.

–  Install new bolts -arrows- for left assembly mounting in gearbox mounting and tighten to specified torque → Chapter.   Note Install engine and gearbox mounting free of tension → Rep. gr.10.   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.

–  Install pendulum support → Running gear, axles, steering; Rep. gr.40. –  Then install drive shafts → Running gear, axles, steering; Rep. gr.40.

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

–  If present, fit front vehicle level sender -G78--arrows-. → Rep. gr.40

–  Attach connector -1- to oil level and oil temperature sender -G266-. –  Assemble exhaust system and attach exhaust system bracket to subframe → Rep. gr.26.

–  Gearboxes for vehicles with start-stop system: join connector -arrow- to gearbox neutral position sender -G701-.

–  Install retainer for electrical wiring -arrow- → Electrical system; Rep. gr.27. –  Install coolant circulation pump -V50--arrow 1-; do not open pipes → Rep. gr.19. –  Install charge air pipe -arrow 2- on engine → Rep. gr.21.

–  Push wire for lambda probe into guides on charge air pipe -arrow 2- and retainer for electrical wiring → Rep. gr.21.

–  Install left charge air hose -1- → Rep. gr.21.

–  Install slave cylinder and tighten bolts -arrows B- to specified torque → Item. –  Then install gearbox support -arrow A- and tighten to specified torque → Chapter.

–  Push connector -1- onto reversing light switch -F4-. –  Attach connector -arrow 2- and wire -arrow 3- to starter → Electrical system; Rep. gr.27. –  Attach earth strap to top starter 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 3- 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. –  Renew securing clip -1- each time it is removed. –  Insert relay lever together with cable end-piece. l  Catch -arrow 2- secures relay lever. l  Ensure proper engagement. The relay lever was secured with a clip shortly after start of production → Fig.. Ensure proper engagement of clip. –  Connect gate selector cable to cable end-piece. –  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 both 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 front left wheel housing liner → General body repairs, exterior; Rep. gr.66. –  Install noise insulation → General body repairs, exterior; Rep. gr.50. –  For vehicles with front vehicle level sender -G78-, check headlight adjustment → Electrical system; Rep. gr.94.