Installing gearbox, vehicles with front-wheel drive — AUDI

🧭 Before you start

Fits: VW Caddy IV (SA, 2015–2020)

• Opens: brake fluid, clutch fluid

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• The dowel sleeves for centring engine and gearbox must be fitted in cylinder block; install if necessary.
• Be careful of all lines when installing gearbox.
• Install engine and gearbox mountings without tension 10Assembly mountings; Assembly overview - Assembly mountings.
• Danger of accident!Do not remove engine support bracket10 - 222 A until all bolts securing the assembly mounting have been tightened to specified torque. — Remove support device10 - 222 A.
• After removing the hose clamp3094, the supply hose must be returned to its original shape.

📋 Procedure

1. If gearbox is renewed, transfer gearbox selector lever to new gearbox.
2. The dowel sleeves for centring engine and gearbox must be fitted in cylinder block; install if necessary.
3. Check release bearing for wear. If necessary, renew clutch slave cylinder with release bearing .
4. Align arms of gearbox support according to holes in adjustment plate.
5. Attach support elements(A) to adjustment plate as illustrated.

6. Screw in pin3282/29 instead of support element(C).
7. Place gearbox on engine and gearbox jack.
8. Align adjustment plate and gearbox parallel to one another.
9. Then screw pin3282/29 into rear hole on gearbox for securing bolt of pendulum support.
10. Secure adapterVW 771/40 in threaded hole of gearbox housing as shown in figure.
11. Secure gearbox to gearbox support3282 using bolt (M10 × 20) (A).
12. Position engine and gearbox jack under vehicle. Arrow on adjustment plate points in direction of vehicle travel. [Note: Be careful of all lines when installing gearbox.]
13. Raise gearbox carefully.
14. Then rotate gearbox into installation position via spindles of gearbox support3282.
15. Align gearbox on engine dowel sleeves and join.
16. ⚠ Brake fluid may escape from bleeder on gearbox. — Screw in lower engine/gearbox connecting bolts (1 … 3), and tighten them .
17. After bottom of gearbox and engine are bolted together, remove gearbox support3282 from gearbox.
18. Remove engine support3300 A and bracket T10346 from subframe.
19. Install noise insulation for sump 17Sump/oil pump; Removing and installing sump.
20. Screw in and tighten all upper engine/gearbox connecting bolts .
21. Install relay lever together with cable end-piece .
22. Install gearbox bracket (1) with new bolts (arrows), and tighten bolts .
23. ⚠ Risk of damaging thread in gearbox bracket if bolts are started at an angle.To avoid damage to the thread in the gearbox bracket, the gearbox mounting and gearbox bracket must be aligned parallel to each other. — Raise engine/gearbox unit using support bracket10 - 222 A until gearbox bracket (1) completely contacts left assembly mounting (2).
24. Screw in new bolts and tighten them (arrows).
25. If fitted, bolt earth strap to front securing bolt for gearbox bracket. [Note: Install engine and gearbox mountings without tension 10Assembly mountings; Assembly overview - Assembly mountings.]
26. ⚠ Danger of accident!Do not remove engine support bracket10 - 222 A until all bolts securing the assembly mounting have been tightened to specified torque. — Remove support device10 - 222 A.
27. Install starter Electrical system27Starter; Removing and installing starter.
28. Gearboxes for vehicles with start/stop system: connect connector (arrow) of gearbox neutral position sender G701.
29. Fit bracket at lower starter bolt, and bolt it on using nut (1).
30. Connect connector (2) for reversing light switch F4.
31. If removed beforehand, install bleeder connection to clutch slave cylinder .
32. Connect pipe/hose assembly or plastic line to bleeder connection .
33. After removing the hose clamp3094, the supply hose must be returned to its original shape.
34. Check for correct installation position of vacuum hose for brake system, fit vacuum hose if necessary Brake system47Brake servo/brake master cylinder.
35. Fit cable support bracket on gearbox, and tighten bolts (2) and nut (1).
36. Insert gate selector cable in cable end-piece.
37. Spread a small amount of grease on pin (arrow) of gearbox selector lever (2).
38. Push gear selector cable onto pin (arrow), and secure it using new securing clip (1).
39. If present, install small cover plate (A) behind right flange shaft. [Note: On some gearboxes, there are threaded inserts, e.g. "“Heli coil”", in the bolting holes for the pendulum support .]
40. Install pendulum support using new bolts 10Assembly mountings; Assembly overview – assembly mountings.
41. Install particulate filter to engine 26Emission control; Assembly overview - emission control.
42. Assemble exhaust system and install exhaust system bracket to subframe (arrows)26Exhaust pipes/silencers; Assembly overview - silencer.
43. Install charge air pipe (arrow)21Charge air system; Assembly overview - charge air system.
44. Secure clamp (2) to particulate filter 26Emission control; Assembly overview - emission control. [Note: Disregard bolts (1).]
45. Tighten bolt (2) of auxiliary pump for heating V488, and connect connector (1)19Coolant pump/coolant regulator unit; Assembly overview - electric coolant pump.
46. Remove protective mat VAS 531003.
47. Install radiator cowl with radiator fans (arrow)19Radiator, radiator fan; Removing and installing radiator cowl.
48. Fit connector (1) to oil level and oil temperature sender G266.
49. Attach drive shafts to gearbox and fasten left drive shaft to wheel bearing housing Running gear, axles, steering40Drive shaft; Removing and installing drive shaft.
50. If fitted, install right drive shaft heat shield Running gear, axles, steering40Drive shaft.
51. If removed beforehand, install tank for reducing agent 26SCR system (selective catalytic reduction); Removing and installing tank for reducing agent.
52. Install front left wheel housing liner General body repairs, exterior66Wheel housing liner; Assembly overview - front wheel housing liner.
53. Check oil level in gearbox .
54. Install noise insulation General body repairs, exterior66Noise insulation; Assembly overview - noise insulation.
55. Fit foam sections on upper edge of left and right wings 50Bulkhead; Assembly overview - plenum chamber cover.
56. Install retainer for wiring harness to right bonnet hinge.
57. Bleed clutch mechanism .
58. Adjust selector mechanism .
59. Install battery tray, battery and battery cover Electrical system27Battery; Removing and installing battery.
60. Install complete air filter housing and air intake pipe between air filter and turbocharger 23Air filter; Assembly overview - air filter housing.

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