VW Golf manuals

Volkswagen Golf Service & Repair Manual: Installing gearbox

Install in reverse order of removal, observing the following:
  Note
Renew bolts which are tightened by turning through a specified angle.
Renew self-locking nuts and bolts, and seals, O-rings and gaskets.
Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic Parts Catalogue.
Fit all cable ties in the original position when installing.
Recalibrate the immobiliser after installing a »new« gearbox.
   
–  In some cases, there are brackets on the front of the removed gearbox. Attach these brackets to the »new« gearbox.
 

Installing gearbox

In some vehicles, a cover is fitted over the engaging levers.
The cover prevents dirt getting in.
Specified torque: 8 Nm
Only Polo with petrol engine:
–  Remove right flange shaft.
 

Installing gearbox

–  Screw 2 bolts into flange and counterhold flange shaft with a lever in order to remove and install flange shaft.
–  Remove flange shaft with spring.
–  Close opening in drive shaft using a suitable plug.
All vehicles:
 

Installing gearbox

–  Renew needle bearing -arrow- in crankshaft → Rep. gr.13.
  Note
If the needle bearing in the crankshaft is damaged, the gears cannot be selected properly anymore because the clutch is supported on this bearing.
 

Installing gearbox

–  Fit gearbox onto gearbox support -3282- and secure it in place.
–  Clean input shaft splines and splines of torsional damper, remove corrosion and lubricate splines with only a very thin coating of grease → Electronic Parts Catalogue (ETKA). Remove excessive grease.
 

Installing gearbox

–  Make sure that the dowel sleeves -arrows B- for centring engine and gearbox are fitted in cylinder block and that the intermediate plate is fitted on the dowel sleeves. Insert any missing dowel sleeves.
–  For some engines, makes sure that the intermediate plate is attached to the sealing flange -arrow A-.
–  Carefully raise gearbox using engine and gearbox jack -V.A.G 1383 A- and move it to installation position with gearbox support -3282-.
–  Bolt gearbox to engine.
 

Installing gearbox

If the gearbox has been sealed so that no oil can escape, e.g. after a gearbox repair or after gearbox has been renewed:
–  Remove both plugs from breathers -arrows- and install breather caps (renew if necessary).
 

Installing gearbox

–  Bolt cable support bracket -1- to gearbox.
Install left assembly mounting as follows:
–  Always renew all bolts on left assembly mountings.
Golf, Golf Estate:
 

Installing gearbox

–  Bolt gearbox bracket -1- to gearbox.
 

Installing gearbox

–  The bracket can be moved within its seat with a screwdriver when bolts -2- are tightened → Rep. gr.10.
Polo:
 

Installing gearbox

–  Bolt gearbox bracket to gearbox.
 

Installing gearbox

–  Then, tighten vertical bolts -arrows-.
–  On Polo with diesel engine, install charge air cooler → Rep. gr.21.
All vehicles:
Continue installation in reverse order of removal.
–  If subframe has been removed, install it → Running gear, axles, steering; Rep. gr.40.
–  Install drive shafts → Running gear, axles, steering; Rep. gr.40.
–  Install front left wheel housing liner → General body repairs, exterior; Rep. gr.66.
 

Installing gearbox

–  If present, install heat shield above right drive shaft → Running gear, axles, steering; Rep. gr.40.
–  Install starter → Electrical system; Rep. gr.27.
–  Check selector lever cable adjustment and adjust it if necessary → Chapter.
  Note
Recalibrate the immobiliser after installing a »new« gearbox via vehicle diagnostic testerGuided functions.
Specified torques
Gearbox to engine → Chapter
Gearbox bracket to gearbox → Chapter
Wire retainer to gearbox cover → Chapter
Selector cable support bracket to gearbox → Chapter
Flange shaft to gearbox → Chapter
 

Installing gearbox

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Specified torques for gearbox
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