Volkswagen Workshop Service and Repair Manuals

Installing gearbox –  Please read these important work steps before installing gearbox.

–  In some cases, there are brackets on the front of the removed gearbox. Attach these brackets to the »new« gearbox.

In some vehicles, a cover is fitted over the engaging levers. The cover prevents dirt getting in. Torque setting: 8 Nm

Gearbox with stub shafts -A- Gearbox with flange shafts -B- –  In gearboxes with stub shafts, stub shaft must be reinstalled on »new« gearbox in some cases. For this procedure, refer to → Chapter. There is no need to renew oil seal when doing this. –  Remove right-hand flange shaft of gearbox in order to install gearbox. Gearbox with flange shafts, torque setting → Chapter Bolt has a 6 mm hexagon socket. Bolt can also be removed and installed with socket -V.A.G 1669-.

–  If it hasn't been done already, renew needle bearing in crankshaft → Rep. gr.13. –  Check for proper seating of both dowel sleeves between engine and gearbox. –  Check for proper seating of intermediate plate. –  Guide selector lever cable as soon as possible into its cable support bracket. Check cable as soon as gearbox is raised. Be sure to insert it in cable support bracket »early«. Cable must not be greased! It must be possible to guide the engine and gearbox together by hand until the engine flange and gearbox flange make contact all around. If not, »something has gone wrong«! –  Re-adjust gearbox support until engine and gearbox »are aligned with each other«. –  If necessary, turn crankshaft slightly.

–  After fitting starter motor, check that both breather caps are in place!

–  Securing clip for selector lever cable must be renewed. A securing clip which has been removed is not allowed to be installed again. The clip will have lost its internal tension and so it might fall off. –  Therefore, when installing, always use a »new« securing clip.

–  Ensure that selector lever cable is properly routed during installation. If the sheet metal has been bent downwards when the gearbox was removed, it may cause noises. The cable will vibrate against the sheet metal. –  Observe sheet metal. Press it back up in the tunnel during installation. –  Always adjust selector lever cable → Chapter. –  Initiate basic adjustment → Chapter. Torque settings for gearbox installation → Chapter.