Volkswagen Golf Variant / Jetta. Manual - part 240

 

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Volkswagen Golf Variant / Jetta. Manual - part 240

 

 

of the differential using the spindles of the Transmission Mount

- 3282- .

– Swivel the transmission further and carefully lower it.

Note

Pay attention to all of the lines when lowering the transmission.

Installing

Note

Refer to “Transmission, Removing” to get a list of the special

tools needed. Refer to

⇒ “3.1 Transmission, Removing and Installing”, page 126

 .

Replace the self-locking nuts and bolts.

Replace bolts that were tightened with an additional turn.

Install any cable ties that were loosened or cut off during re‐

moval at their same location.

Clean input shaft splines and (on used clutch plates) the hub

splines, remove corrosion and apply a very thin coating of

Grease for Clutch Disc Shaft Splines - G 000 100- to the

splines. Then move the clutch plate back and forth on the input

shaft until the hub moves freely on the shaft. Excess grease

must be removed.

– If the transmission is replaced, transfer the transmission shift

lever and the relay lever.

– Clean any locking compound residue from all threaded holes

using a tap.

– Check whether there are centering sleeves for the engine/

transmission in the cylinder block; install if necessary.

If the alignment sleeves are missing, it will be difficult to shift, there

will be clutch problems and the transmission may make noises

(loose rattling).

3. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehicles with

Gasoline Engine and FWD    

135

flange and pushed onto the alignment sleeves -arrows-.

– Check the release bearing for wear. Replace the clutch slave

cylinder with release bearing if necessary. Refer to

⇒ “2.2 Clutch Slave Cylinder with Release Bearing, Removing

and Installing”, page 52

 .

– Tighten the Engine Support Bridge - Gearbox Bracket -

T10346- with the bolt -1- in the left threaded hole in the

subframe.

– Install the Engine Support Bridge - Gearbox Bracket - T10346-

in the same angled position as the engine.

-1- = M6 x 20 collar bolt
– Secure the Engine Support Device - 3300A- on the Engine

Support Bridge - Gearbox Bracket - T10346- .

– Push the engine forward using the spindle on the Engine Sup‐

port Device - 3300A- . Note the following when doing this:

• The A/C compressor -2- must not touch the refrigerant line

-1- -arrow-.

• The generator must not touch the refrigerant line.
• The pressure pipe must not touch the radiator.
Align the Transmission Support - 3282- with the Transmission

Support - Mounting Plate 33 - 3282/33- in order to install the “02Q”

transmission.
– Align the arms of the Transmission Support so that they match

up with the holes in the Adjustment Plate .

– Install the Support Elements -A- as illustrated on the Adjust‐

ment Plate .

– Install the Transmission Support - Pins 29 - 3282/29- in place

of the Mounting Element -C-.

– Place the transmission on the Engine and Gearbox Jack -

VAS6931- .

– Align the Adjustment Plate so that it is parallel to the trans‐

mission.

– Install the Transmission Support - Pins 29 - 3282/29- into the

hole on the transmission for the pendulum support bolt.

136

the threaded hole in the transmission housing as shown.

– Secure the transmission on the Transmission Support - 3282-

with an M10 x 20 bolt -A-.

The drift -B- must be flush at the bottom with the guide on the

Transmission Support - 3282- -arrow-.
– Position the Engine and Gearbox Jack - VAS6931- under the

vehicle. The arrow on the adjusting plate points in direction of

travel.

Note

Pay attention to all of the lines when installing the transmission.

– Using the spindles of the Transmission Support - 3282- , adjust

the transmission so that the differential area is rotated in di‐

rection of -arrow- upward.

– Lift the transmission carefully.

– Guide the transmission and differential -A- over the subframe.

– Pay attention to the longitudinal member -arrows-.
– Move the transmission toward the rear to the subframe.

3. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehicles with

Gasoline Engine and FWD    

137

flywheel and the cut-out -arrow- in the intermediate plate.

– Turn the transmission to its installed position using the spin‐

dles of the Transmission Support - 3282- .

– Align the transmission to the engine (alignment sleeves) and

insert it.

– Insert engine/transmission bolt -C- and tighten to tightening

specification. Refer to

⇒ “3.2 Tightening Specifications”, page 143

 .

– Install the engine/transmission connecting bolt -arrow- and

tighten it to the tightening specification. Refer to

⇒ “3.2 Tightening Specifications”, page 143

 .

– Remove the Engine Support Device - 3300A- and Engine

Support Bridge - Gearbox Bracket - T10346- .

– Install lower engine/transmission connecting bolts and tighten

to tightening specification. Refer to

⇒ “3.2 Tightening Specifications”, page 143

 .

– After transmission is bolted to engine at bottom, remove the

Transmission Support - 3282- from transmission.

– Install the upper engine/transmission connecting bolts and

tighten them to the tightening specification. Refer to

⇒ “3.2 Tightening Specifications”, page 143

 .

– Attach the transmission gearshift lever to the gearshift shaft.

Refer to

⇒ Fig. ““Installing the Transmission Shift Lever”“ , page 88

 and

tighten the nut to tightening specification -item 17-

⇒ Item 17 (page 87)

 .

Metal Relay Lever
– Install the relay lever -1- and the lock washer -arrow-.
Plastic Relay Lever
– Install the relay lever with the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89

 .

Continuation for All

138

 

 

 

 

 

 

 

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