Transmission, Installing

Transmission, installing (vehicles with 4-cylinder or 6-cylinder engine), 02X, 6-Speed Four-Wheel Drive M/T
Installation is in reverse order of removal. Note the following:
- Use thread tap to remove any remaining locking fluid from all threaded holes which will accommodate self-locking bolts.
- Always replace self-locking bolts and nuts.
- Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splines G000100 to splines. Do not grease guide sleeve.

It should be possible to push clutch plate back and forth slightly on input shaft.





- Check clutch release bearing for wear and replace if necessary.
- If plastic ring - arrows - has come loose, service release bearing as required.

Note:
^ The release bearing must be replaced if the groove worn on the plastic ring is deeper than 0.8 mm.

- Check that dowel sleeves for centralizing engine/transmission are in the cylinder block, install if necessary.
- Place intermediate plate on dowel sleeves at engine flange.
- Before installing transmission, tie electrical wires and brackets off to one side so that they are not trapped between engine and transmission.
- Lightly lubricate surface where operating rod and clutch release lever make contact arrowB using copper grease Z381351TE.
- Raise transmission far enough to be able to install slave cylinder with bracket for hose/line assembly.





- Guide slave cylinder - 1 - into opening in transmission housing keeping it as straight as possible (without tilting operating rod - arrow A -) and insert in recess - arrow B - on clutch release lever - 3 -.

Note:
^ If the slave cylinder - 1 - is inserted at an angle, there is a danger that the operating rod - arrow A will be guided past the clutch release lever - 3 -.

CAUTION!
After installing the slave cylinder carefully press the clutch pedal. If you feel an unusually strong point of pressure when depressing the clutch pedal, do not press it down further. The push rod of the slave cylinder is likely to have been guided past the clutch release lever. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N.





- Secure slave cylinder with new bolt - arrow -.
- Insert transmission, making sure there is sufficient clearance to drive shafts.





- Install engine/transmission securing bolts - arrow A - and - arrow B -.
- Install starter.





- Carefully lower transmission a short distance using engine and transmission jack VAG 1383 A.
- If possible, tighten upper engine/transmission securing bolts - arrows1 - and - arrows2 -.





- If installed, secure all electrical wiring to transmission again - arrowsA to C -.





- Install selector shaft lever and tighten nut - arrow -.





- Connect connector - arrow - for back-up light switch F 4 on right side of transmission.





- Install push rod - 1 - by tightening hex socket head bolt.
- Secure connecting rod - 2 - for selector rod.





- If installed, install Engine Speed (RPM) Sensor G28 on left side of transmission.





- Lift transmission again using engine/transmission jack V.A.G 1383 A.
- Attach cross member to body with new bolts - 2 - and - 3 - (tighten hand-tight only).
- Secure cross member to transmission mounting - 4 -.
- Carefully lower engine/transmission jack VAG 1383 A and move it aside.
- Bolt drive axles - 1 - to flange shafts.





- It is important to clean threaded holes for drive axle bolts to remove any remaining locking fluid. The threads can be cleaned with a thread tap.
- Bolt drive axle onto transmission - arrows -.





- If installed, install heat shield for drive shaft - arrows -.





Vehicles with 6-cylinder engine:

Take up weight of engine with support bracket 10 - 222 A.
- Remove front bolts - 2 - and - 3 - on subframe (left and right). Then remove bolts - 1 -.
- Lower subframe at front.





- Tighten three lower engine/transmission securing bolts at bottom - arrows -.





- Replace front subframe bolts - 1 -, - 2 - and - 3 - on both sides of vehicle.





Before tightening subframe, it must be aligned with body using testing mandrel 3393.
Hole - 1 - and hole - 2 - of subframe and hole - 3 - of aluminum bracket must be flush on both sides.

Note:
^ This alignment can only replace a subsequent wheel alignment if holes - 1 - and - 2 - coincided before the repair work was performed.





- Tighten nuts - 1 - for engine mountings.





Cabriolet vehicles with 4-cylinder engine:
- Lift engine slightly using spindles.





- Tighten bottom engine/transmission securing bolts - arrows -.
- Lower engine back down.





- Secure torque reaction support - arrows -.





- Tighten nuts - 1 - for engine mountings.

Continued for all vehicles:
Secure subframe and cross member.

Install exhaust system so it is free of stress.

Check selector mechanism setting and adjust if necessary.

Check gear oil level in transmission.

Follow steps required after connecting battery.

If necessary, perform wheel alignment.

Wheel alignment is not necessary if subframe was secured to body using testing mandrel 3393 prior to disassembling and assembly of subframe (before tightening bolts).

Wheel alignment must, however, be performed, if the subframe was not secured to body using testing mandrel 3393 or if it was not possible to fully insert the two drifts into holes.

Tightening torques

Note:
^ Tightening torques only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
^ Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant.

Do not use parts which have been degreased.
Tolerance for tightening torques ± 15%.





Engine/transmission attachment (1.8 liter engine)








Engine/transmission attachment (2.0 liter engine)





A: dowel sleeves for centralizing





Engine/transmission attachment (6-cylinder 3.0 liter engine)