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 hooked into sealing flange and pushed onto dowel sleeves -arrows-. –  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 four-wheel drive”, 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 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 gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel. –  Then carefully raise gearbox.   Note t  When installing gearbox, observe electromechanical steering box. t  Be careful of all lines when installing gearbox. –  Change position of gearbox using spindles of gearbox support -3282-. –  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 gearbox jack from gearbox.

–  Install small cover plate -A- behind bevel box, if present -arrow-. –  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 hooks -10 - 222 A /10- of support bracket -10 - 222 A-. –  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 right support -A- for exhaust manifold → Rep. Gr.26.

–  Bolt bevel box carrier to engine and bevel box, observing assembly sequence → Chapter. –  Attach left and right drive shafts to gearbox → Running gear, axles, steering; Rep. Gr.40.

–  If present, attach shield for right drive shaft to bevel box -arrows-. –  Install subframe and suspension links → Running gear, axles, steering; Rep. Gr.40.

–  Bolt propshaft with flexible coupling to bevel box flange -arrows- → Rep. Gr.39.

Attach pendulum support with new bolts -2- and -3- to gearbox → Running gear, axles, steering; Rep. Gr.40.

–  Install left support for exhaust manifold -A- on bevel box and exhaust manifold (bolts -2- and -3-) → Rep. Gr.26. –  Attach connector -1- to oil level and oil temperature sender -G266-. –  Assemble exhaust system and attach exhaust system bracket to subframe → 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.

–  Screw breather pipe -arrow-, if present, into bevel box and tighten to 10 Nm. –  Install earth strap at upper engine/gearbox connecting bolt.

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

l  Bracket -B- must be attached 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-. –  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-. –  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 cover and battery → Electrical system; Rep. Gr.27. –  Install complete air filter housing → Rep. Gr.24. –  Install engine cover. –  Reconnect battery and perform work required after connecting battery → Electrical system; Rep. Gr.27. –  Check gear oil in bevel box → Chapter. –  Install front parts of front left and right wheel housing liners → General body repairs, exterior; Rep. Gr.66. –  Install noise insulation → General body repairs, exterior; Rep. Gr.50. –  Install wheels → Running gear, axles, steering; Rep. Gr.44. –  For vehicles with front sender for vehicle level, check headlight adjustment → Electrical system; Rep. Gr.94