Installing gearbox, Golf, Golf Estate, front-wheel drive vehicle with petrol engine — VW

🧭 Before you start

Prepare the splines, dowel sleeves and threaded holes, and check the release bearing. Mount the gearbox on support 3282, raise and tilt it past the subframe and join it to the engine. Fit the lower then upper connecting bolts, remove the support, and fit the bracket and mounting with new bolts after aligning the assembly. Bleed the clutch, refit the selector mechanism, starter, cooling, charge air, exhaust, pendulum support and drive shafts, then check gear oil level.

Fits: VW Golf VII Variant (BA), VW Golf VII (5G, 2012–2020)

• Opens: brake fluid, clutch fluid, gearbox oil
• Renewed: self-locking nuts

Don't miss

• Renew self-locking nuts and bolts, and angle-tightened bolts, after each removal.
• Clean threaded holes of old locking fluid with a thread tap.
• Leave the engine support bracket on until all mounting bolts are torqued.
• Align the gearbox mounting and bracket parallel so the threads are not cross-started.
• Renew the selector securing clip and bleed the clutch afterwards.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. If a front differential lock is fitted, , install manual gearbox and front differential lock together. [Note: Refer to procedure "“Removing gearbox”" for required special tools .Renew self-locking nuts and bolts after each removal.Renew bolts that are tightened with turning further angle after each removal.All cable ties which were opened or cut during removal must be renewed at the same points.Clean input shaft splines and, on used clutch plate, hub splines. Remove corrosion and apply only a very thin coat of clutch plate spline grease to splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease.]
2. If the gearbox is to be renewed, the gearbox selector lever and gate relay lever must be transferred to the new gearbox.
3. All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.
4. The dowel sleeves for centring engine and gearbox must be fitted in cylinder block, install if necessary.
5. Check release bearing for wear. If necessary, renew clutch slave cylinder with release bearing .

6. Align arms of gearbox support according to holes in adjustment plate.
7. Attach support elements(A) to adjustment plate as illustrated.
8. Screw in pin3282/29 instead of support element(C).
9. Place gearbox on engine and gearbox jack.
10. Align adjustment plate and gearbox parallel to one another.
11. Then screw pin3282/29 into rear hole on gearbox for securing bolt of pendulum support.
12. Secure adapterVW 771/40 in threaded hole of gearbox housing as shown in figure.
13. Secure gearbox to gearbox support3282 using bolt (M10 × 20) (A).
14. 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.]
15. Now turn gearbox near differential via spindles of gearbox support3282 in (direction of arrow).
16. Then carefully raise gearbox.
17. If necessary, tilt gearbox further using spindles of gearbox support3282.
18. Have a second mechanic push engine towards front end slightly.
19. Guide gearbox with differential over subframe (A)(in direction of arrow).
20. Guide gearbox with differential over subframe and swing it out.
21. Observe longitudinal member (arrow 1) and subframe (arrow 2).
22. Swing rear of gearbox towards subframe.
23. Then rotate gearbox into installation position via spindles of gearbox support3282.
24. Align gearbox on engine dowel sleeves and join.
25. ⚠ Brake fluid may escape out of bleeder on gearbox. — Screw in engine/gearbox connecting bolt (C) and tighten it (⇒ illustration above) .
26. Screw in engine/gearbox connecting bolts (1) and (2), and tighten them .
27. Screw in and tighten all lower engine/gearbox connecting bolts .
28. After bottom of gearbox and engine are bolted together, remove gearbox support3282 from gearbox.
29. Screw in all upper engine/gearbox securing bolts and tighten them .
30. Install gearbox selector lever to gearbox selector shaft and tighten hexagon nut .
31. Install gate relay lever together with cable end-piece .
32. ⚠ Risk of damaging thread in gearbox support if bolts are started at an angle.To avoid damage to the thread in the gearbox support, the gearbox mounting and bracket must be aligned parallel to each other. — Install gearbox bracket (1) with new bolts (arrows).
33. Align engine/gearbox assembly in installation position; to do so, tighten spindles of engine support bracket10 - 222 A until gearbox support (1) makes contact with gearbox mounting (2).
34. Screw in new bolts and tighten them (arrows). [Note: Install engine and gearbox mounting free of tension 10Removing and installing engine; Installing engine.]
35. If present, install earth wire (arrow).
36. Do not remove engine support bracket10 - 222 A until all bolts securing the assembly mounting have been tightened to specified torque.
37. Connect pipe/hose assembly to bleeder connection .
38. After removing the hose clamp3094, the supply hose must be returned to its original shape.
39. Bleed clutch mechanism .
40. Check for correct installation position of vacuum hose for brake system. Fit vacuum hose if necessary Brake system47Brake servo/main brake cylinder.
41. Install cable support bracket to gearbox and tighten bolts and nuts (arrows).
42. Insert gate selector cable in cable end-piece.
43. Spread a small amount of grease on pin (arrow) of gearbox selector lever (2).
44. Renew securing clip (1) after each removal.
45. Adjust selector mechanism
46. Install starter Electrical system27Starter.
47. If necessary, install bleeder connection .
48. Connect connectors on front left of gearbox:
49. Install radiator cowl with radiator fan (arrow)19Radiator, radiator fan; Removing and installing radiator cowl.
50. Install charge air hose (1)21Charge air system; Assembly overview - charge air system.
51. Assemble exhaust system 26Emission control; Assembly overview – emission control.
52. Install pendulum support with new bolts 10Assembly mountings; Assembly overview - assembly mountings. [Note: On some gearboxes, there are threaded inserts, e.g. "“Heli coil”", in the bolting holes for the pendulum support .Install engine and gearbox mounting free of tension 10Removing and installing engine.]
53. Connect connector (arrow) to transverse lock-up control unit J647.
54. Install drive shafts Running gear, axles, steering40Drive shaft; Removing and installing drive shaft.
55. If fitted, install drive shaft heat shield (illustrated together with front differential lock) Running gear, axles, steering40Drive shaft.
56. If removed, install front left vehicle level sender G78Running gear, axles, steering43Vehicle level sender; Assembly overview - front vehicle level sender.
57. Fit connector (1) to oil level and oil temperature sender G266.
58. Check oil level in gearbox Checking gear oil level.
59. Check oil level in Haldex coupling of front differential lock .
60. If unclipped, carefully clip in pipe for air conditioning. Do not disconnect pipe/hose system Heating, air conditioning87Refrigerant circuit; System overview - refrigerant circuit.

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