Installing gearbox, vehicles with 2.5 l - 110 kW and 2.5 l - 125 kW engines — VW

🧭 Before you start

Fits: VW Golf V / Jetta (1K, 2003–2009); platform code AJ5

• Renewed: all bolts

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• After installing, check ATF level .

📋 Procedure

1. Check whether dowel sleeves are pressed into engine flange.
2. Check seat of intermediate plate between engine and gearbox. The plate must make contact with the engine along its entire perimeter when it is pressed gently with both hands against the engine. If the top does not contact the engine, it is not properly engaged in the engine block.
3. Check that torque converter is installed correctly .
4. Renew all bolts on left assembly mounting.
5. First screw in all bolts by hand.

6. Align engine and gearbox in installation position. To do this, lift up sufficiently until gearbox bracket is fully in contact with gearbox mounting.
7. ⚠ Risk of damaging thread in gearbox bracket if bolts are started at an angle.Before starting the bolts (2), gearbox bracket and support arm of gearbox mounting must be perfectly aligned parallel to each other. If necessary, raise the back of the gearbox using the engine and gearbox jack. — Install pendulum support Running gear, axles, steering40Subframe, anti-roll bar, suspension links; Assembly overview - subframe, anti-roll bar, suspension links.
8. Install drive shafts in gearbox Running gear, axles, steering40Removing and installing drive shafts; Removing and installing drive shafts with triple-roller joint AAR2600i.
9. Align exhaust system free of stress 26Exhaust system or 26Parts of exhaust system.
10. Install starter Electrical system27Starter; Removing and installing starter.
11. Connect coolant hoses to ATF cooler and check coolant level 19Parts of cooling system.
12. Install and adjust selector lever cable on gearbox .
13. Install battery tray and battery Electrical system27Battery; Removing and installing battery.
14. After installing, check ATF level .
15. Install noise insulation General body repairs, exterior50Noise insulation; Assembly overview - noise insulation.
16. Install wheels Running gear, axles, steering44Torque settings for mounting wheels.
17. Carry out basic settings. To do this, connect and then choose Guided functions to "“Perform basic setting”".

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