Transmission, Installing

Install in reverse order of removal. Note the following:

-- Check the needle bearing -arrow- inside the crankshaft. Replace if it is damaged or has blue tarnish. Refer to CRANKSHAFT NEEDLE BEARING .

Fig 1: Checking Needle Bearing Inside Crankshaft

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-- Coat it lightly with High Temperature Grease G 052 133 A2 if it is not damaged.

-- Transmission pins (not splines) must also be lightly lubricated.

-- Make sure both alignment sleeves between the engine and the transmission fit correctly.

-- Make sure the intermediate plate fits correctly.

Pay attention to the selector lever cable when lifting the transmission. Guide the selector lever cable into the cable bracket as early as possible.

The cable is not lubricated.

Guide the engine and transmission together by hand until the entire surface of both flanges come into contact with one another.

-- Adjust the transmission mount until the engine and transmission are aligned.

-- Turn the crankshaft slightly if necessary.

-- Insert transmission without pinching any lines.

-- Attach transmission to engine. Tightening Specifications  , Transmission to Engine. Refer to TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS .

Install the left subframe mount as follows:

Fig 2: Identifying Transmission Support Plate And Bolts

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-- Replace all bolts -1- and -2- for the left subframe mount.

-- Install all the new bolt first hand-tight.

-- Fasten the transmission bracket -A- 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.

Install the engine/transmission mount free of tension. Refer to Installing .

-- Tighten the bolts -2- to the tightening specification.

-- Remove Engine Support Bridge 10 - 222 A.

-- Install starter. Refer to Removal and Installation .

Connect the connector -A- on the DSG Transmission Mechatronic -J743- as follows:

Fig 3: View Of Installing Connector -A- On DSG(R) Transmission Mechatronic -J743

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-- The arrow -D- on the Mechatronic -B- must line up with the connector -A- as well as with the tab -C-.

-- Connect the connector -A- carefully all the way and then turn the lock clockwise in -direction of arrow-.

-- Attach the driveshafts to the transmission. Refer to Removal and Installation .

-- Install the heat shield over the right driveshaft. Refer to Removal and Installation .

-- Install the subframe and steering gear. Refer to Removal and Installation .

-- Install the pendulum support with new bolts on the transmission. Refer to ENGINE AND TRANSMISSION MOUNT OVERVIEW .

Fig 4: Identifying Pendulum Support

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-- Selector lever cable lock washers -arrows- must be replaced.

Fig 5: Identifying Lock Washers

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-- Always adjust selector lever cable SELECTOR LEVER CABLE, CHECKING AND ADJUSTING .

-- Attach the coolant hoses to the transmission fluid cooler.

-- Check the coolant level and fill if necessary. Refer to COOLANT, DRAINING AND FILLING .

-- Assemble exhaust system and fasten exhaust system bracket to subframe. Refer to EXHAUST SYSTEM, INSTALLING WITHOUT TENSION .

-- Install the plenum chamber cover. Refer to Removal and Installation .

-- Install the lock carrier trim and the bolts -arrows- for the left and right front end brackets. Refer to Removal and Installation .

Fig 6: Identifying Bolts

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-- Install the battery tray and the battery. Refer to Removal and Installation .

-- Install the complete air filter housing:

• Gasoline engine. Refer to Installing .
• TDI engine. Refer to [For engine(s) CJAA] Removal and Installation .

-- Connect the battery and follow the procedure regarding what to do after connecting a battery. Refer to Removal and Installation .

-- Install the engine cover. Refer to Installing .

-- Check the transmission fluid level and if necessary fill. Refer to TRANSMISSION FLUID LEVEL, CHECKING .

-- Install the left and right front wheel housing liner. Refer to Removal and Installation .

-- Install the noise insulation. Refer to Removal and Installation .

-- Attach the front wheels. Refer to Removal and Installation .

Tightening Specifications: 

• Transmission to engine. Refer to TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS .
• Left assembly mounts. Refer to ASSEMBLY MOUNTS ASSEMBLY OVERVIEW .
• Cable mounting bracket to transmission. Refer to SELECTOR MECHANISM ASSEMBLY OVERVIEW .