Volkswagen Golf Variant / Jetta. Manual - part 584

 

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Volkswagen Golf Variant / Jetta. Manual - part 584

 

 

Always replace the needle bearing -arrow- after separating the

engine and transmission.

If the needle bearing in the crankshaft is damaged, the gears

will no longer shift correctly.

Gr.  13 ; Crankshaft; Needle Bearing in Crankshaft, Replacing .

Transport the transmission and secure to the assembly stand.

Refer to

⇒ “6 Transmission, Transporting and Securing To Assembly

Stand”, page 191

 .

Install the transmission. Refer to

⇒ “4.6 Transmission, Installing, Jetta from MY 2005, Golf Wagon

from MY 2007, Golf Wagon from MY 2010”, page 157

 .

If the transmission is going to be shipped:

The bracket is located on the front of the transmission in some

cases.
– Remove the bracket if a »new« transmission is being installed,

because brackets are not equipped on »new« transmissions.

– Install the right flange shaft on a transmission with flange

shafts. Refer to

⇒ “1.4 Right Flange Shaft Seal, Replacing”, page 210

 .

4.6

Transmission, Installing, Jetta from MY

2005, Golf Wagon from MY 2007, Golf

Wagon from MY 2010

– Please read these important steps before installing the trans‐

mission.

– The bracket is located on the front of a removed transmission

in some cases. Reattach this bracket to the »new« transmis‐

sion.

4. Transmission, Removing and Installing, Jetta from MY 2005, Golf Wagon from MY 2007 and Golf Wagon from MY 2010    

157

Transmission with Stub Shafts -A-
Transmission with Flange Shafts -B-
– Remove the right transmission flange shaft to install the trans‐

mission.

– The flange shaft must be reattached to the transmission after

installing it. Refer to

⇒ “1.4 Right Flange Shaft Seal, Replacing”, page 210

 .

Note

The flange shaft seal does not need to be replaced for this.

The bolt has 6 mm inner hex. The bolt can also be removed and

installed using the Long Hex Socket - VAG1669- .

158

Note

Always replace the needle bearing -arrow- after separating the

engine and transmission.

If the needle bearing in the crankshaft is damaged, the gears

will no longer shift correctly.

– If not already done, replace the needle bearing in the crank‐

Crankshaft, Replacing .

– Make sure both alignment sleeves between the engine and

the transmission are correctly seated.

– Make sure the intermediate plate fits correctly.
– Guide the selector lever cable into the cable bracket as soon

as possible.

Check the selector lever cable when raising the transmission. Do

not forget to insert it »early« into the cable bracket.
Do not grease the selector lever cable.
Guide the engine and transmission together by hand until the en‐

tire surface of both flanges come into contact with one another.
If they do not, »something is incorrect«!
– Adjust the transmission mount until the engine and transmis‐

sion »are aligned«.

– Turn the crankshaft slightly if necessary.
– Insert the transmission without pinching any lines.
– Attach the transmission to the engine.
– Remove the Transmission Support - 3282- from the transmis‐

sion.

4. Transmission, Removing and Installing, Jetta from MY 2005, Golf Wagon from MY 2007 and Golf Wagon from MY 2010    

159

transmission mount support arm.

– First attach the transmission bracket to the transmission using

the bolts -1-.

– Align the engine/transmission in its installed position. Lift until

the transmission bracket is touching the transmission mount

completely.

Caution

There is a risk of damaging the threads in transmission bracket

by inserting bolts at an angle.

♦ Before installing the bolts -2-, the transmission bracket

and transmission mount support arm must be absolutely

parallel to each other. If necessary, lift the back of the

transmission using the Engine and Gearbox Jack .

Install the engine/transmission mount without tension. Refer to ⇒ 

Rep. Gr.  10 .
– Tighten the bolts -2- to the tightening specification.

WARNING

Only remove Engine Support Bridge - 10-222A- when all the

left and right subframe mount bolts are tightened to the tight‐

ening specification.

– Always replace the selector lever cable lock washer -arrow-.
Do not install a used lock washer. The washer can wear if it loses

its residual stress.
– Always use a »new« lock washer during assembly.

– When installing, make sure the selector lever cable is routed

correctly in direction of -arrow-.

If the heat shield underneath is bent, there will be noises. The

selector lever cable will then »flap« on the heat shield.
– Pay attention to the heat shield. Push it into the tunnel when

installing.

– Install the starter. Refer to ⇒  Electrical Equipment; Rep. Gr. 

27 ; Starter; Starter, Removing and Installing .

160

 

 

 

 

 

 

 

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