Installing gearbox, vehicles with petrol engine — VW

🧭 Before you start

Fits: platform codes AU1, BX5

• Opens: brake fluid, clutch fluid, gearbox oil

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• If the gearbox is to be renewed, the gearbox selector lever and relay lever must be transferred to the new gearbox.
• All threaded holes into which self-locking bolts are to be screwed must be carefully cleaned of residual locking fluid using a thread chaser.
• 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.

📋 Procedure

1. If the gearbox is to be renewed, the gearbox selector lever and relay lever must be transferred to the new gearbox.
2. All threaded holes into which self-locking bolts are to be screwed must be carefully cleaned of residual locking fluid using a thread chaser.
3. The dowel sleeves for centring engine and gearbox must be fitted in cylinder block; install if necessary.
4. Check release bearing for wear. If necessary, renew clutch slave cylinder with release bearing .
5. Align arms of gearbox support according to holes in adjustment plate.

6. Attach support elements(A) to adjustment plate as illustrated.
7. Screw in pin3282/29 instead of support element(C).
8. Place gearbox on engine and gearbox jackV.A.G 1383 A.
9. Align adjustment plate and gearbox parallel to one another.
10. Then screw pin3282/29 into rear hole on gearbox for securing bolt of pendulum support.
11. Secure adapterVW 771/40 in threaded hole of gearbox housing as shown in figure.
12. Secure gearbox to gearbox support3282 using bolt (M10 × 20) (A).
13. Position engine and gearbox jackV.A.G 1383 A under vehicle. Arrow on adjustment plate points in direction of vehicle travel. [Note: Be careful of all lines when installing gearbox.]
14. Now turn gearbox near differential via spindles of gearbox support3282 in (direction of arrow).
15. Then carefully raise gearbox.
16. If necessary, tilt gearbox further using spindles of gearbox support3282.
17. Have a second mechanic push engine towards front end slightly.
18. Guide gearbox with differential over subframe (arrow 2).
19. Note longitudinal member (arrow 1).
20. Then rotate gearbox into installation position via spindles of gearbox support3282.
21. Align gearbox on engine dowel sleeves and join.
22. ⚠ Brake fluid may escape from bleeder on gearbox. — Screw in engine/gearbox connecting bolts (1…3) and tighten them .
23. After bottom of gearbox and engine are bolted together, remove gearbox support3282 from gearbox.
24. Screw in all upper engine/gearbox securing bolts and tighten them .
25. Install gearbox selector lever to gearbox selector shaft and tighten hexagon nut .
26. Install relay lever together with cable end-piece .
27. Install gearbox bracket (1) with new bolts (arrows).
28. ⚠ 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. — Align engine/gearbox assembly in installation position; to do so, tighten spindles of engine support bracket10 - 222 A until gearbox bracket (1) makes contact with gearbox mounting (2).
29. Screw in new bolts and tighten them (arrows). [Note: Install engine and gearbox mountings without tension 10Assembly mountings; Assembly overview - Assembly mountings.]
30. If present, install earth wire (arrow).
31. ⚠ Danger of accident!Do not remove engine support bracket10 - 222 A until all bolts securing the assembly mounting have been tightened to specified torque. — Connect pipe/hose assembly to bleeder .
32. After removing the hose clamp3094, the supply hose must be returned to its original shape.
33. Bleed clutch mechanism .
34. Check for correct installation position of vacuum hose for brake system. Fit vacuum hose if necessary Brake system47Brake servo/main brake cylinder.
35. Install cable support bracket to gearbox and tighten bolts and nuts (arrows).
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. Renew securing clip (1) after each removal.
39. Adjust selector mechanism .
40. Install starter Electrical system27Starter; Assembly overview – starter.
41. Connect electrical connectors on front left of gearbox:
42. Install radiator cowl with radiator fan (arrow)19Radiator, radiator fan; Removing and installing radiator cowl.
43. Install charge air hose (1)21Charge air system; Assembly overview - charge air system.
44. Assemble exhaust system 26Exhaust pipes/silencers; Assembly overview - silencer.
45. Install pendulum support using 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 .]
46. Install drive shafts Running gear, axles, steering40Drive shaft; Removing and installing drive shaft.
47. Install lower suspension link Running gear, axles, steering40Lower suspension link; Assembly overview - lower suspension link, swivel joint.
48. If fitted, install drive shaft heat shield Running gear, axles, steering40Drive shaft; Removing and installing drive shaft heat shield.
49. If removed, install front left vehicle level sender G78 on lower suspension link Running gear, axles, steering43Vehicle level sender; Assembly overview - front vehicle level sender.
50. Fit connector (1) to oil level and oil temperature sender G266.
51. Check oil level in gearbox Checking gear oil level.
52. If unclipped, carefully clip in pipe for air conditioning. Do not disconnect pipe/hose system Heating, air conditioning87Refrigerant circuit; System overview - refrigerant circuit.
53. Install battery tray, battery and battery cover Electrical system27Battery; Removing and installing battery.
54. Install complete air filter housing 24Air filter; Removing and installing air filter housing.
55. Install engine cover panel 10Engine cover panel; Removing and installing engine cover panel.
56. Install lower part of front left wheel housing liner General body repairs, exterior66Wheel housing liner; Assembly overview - front wheel housing liner.
57. Install noise insulation General body repairs, exterior66Noise insulation; Assembly overview - noise insulation.

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