Installing gearbox

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Installing gearbox
Cleaninputshaftsplinesandlightlygreasewithgrease-G 000100-. Theclutchplatemustslideeasilytoandfroontheinputshaft. Checkwhetherdowelsleevesforaligningengineandgearbox arefittedincylinderblockandinstallifnecessary. Ifdowelsleevesarenotfitted,difficultiesshiftinggear,clutch problemsandpossiblenoisesfromthegearbox(rattlingofgears whicharenotengaged)couldoccur. Ensurethatintermediateplateiscorrectlyseatedonengine. Boltsupportrail-VW457/1-tosubframeat securingholesforpendulumsupport. Spacerstotalling6mmmustbeinserted betweensubframeandsupportrailVW457/1-. A-2hexagonboltsM8x25 Fitsupport-3300A-andbolton-arrows-. Vehicles with a 1.4 l engine

Attachenginesupport-3300A-toengine nexttoexhaustpipe. Continuation for all vehicles Pressengineforwardcarefully.

Assemblegearboxjackwithgearbox support-3282-,adjustmentplate-3282/5- for020gearboxandsupportelementsas follows: Fitadjustmentplate-3282/5-ongearbox support-3282-(adjustmentplatefitsin onlyoneposition). Alignarmsofgearboxsupportaccordingto holesinadjustmentplate.

Screwinsupportelements-A-as illustratedonadjustmentplate. Placegearboxongearboxjack. Alignadjustmentplateandgearbox paralleltoeachotherandlocksafety supportongearbox.

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Installing gearbox

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Placegearboxjackundervehiclewith arrowsymbol-B-(AnchorFig.V342577)onadjustmentplatepointingtofront ofvehicle. Alignadjustmentplateparalleltogearbox andlocksafetysupportongearbox. Insertgearbox. Installlowerengine/gearboxsecuring bolts.

Removeenginesupport-3300A---.

Thenremovebolts-A-andremovesupport rail-VW457/1-.

Installlowerengine/gearboxsecuringboltarrowA-.

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Installing gearbox

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Alignengineandgearboxininstallation position.Todothis,tightenleftspindleof supportbar-10-222A-. InstallpendulumsupportRunninggear, axles,steering-frontandfour-wheel drive;Rep.Gr.40 Usenewboltsforsecuring.

Ifpresent,installsmallcoverplate-A- behindrightdriveflange--. Ifpresent,installlargecoverplatefor clutch. AttachdriveshaftstogearboxRunning gear,axles,steeringfrontandfour-wheel drive;Rep.Gr.40.

Ifshieldforrightinnerconstantvelocityjoint ispresent,installit--.Runninggear, axles,steering;Rep.Gr.40. InstallstarterElectricalsystem;Rep. Gr.27.

Installslavecylinder--.

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Installing gearbox

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Reconnectspeedometersenderconnector -arrow4-. Installgearboxbracket-arrows3-andarrow1-withnewhexagonbolts. Installnewhexagonbolts-arrows2-forleft assemblymountingingearboxmounting. WARNING

Donotremovesupportbracket-10-222 A-untiltheboltssecuringtheleft gearboxbrackethavebeentightenedto specifiedtorque. Attachretainerforpowersteeringlineto rearboltofgearboxbracket-arrow1-. Installupperengine/gearboxconnecting bolts. Through gearbox date 02 08 8 Pushonreversinglightconnector-arrow-. From gearbox date 03 08 9

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Installing gearbox

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Reconnectreversinglightconnectorarrow3-. Vehicles with 1.4 l engine Installretainerforlambdaprobe-arrow1- andsecurewithbolt-arrow2-. Torquesettings:

Boltforretainer Continuation for all vehicles

25Nm

Reconnectallotherelectricalconnectionsandearthwiresto gearboxandtoengine/gearboxsecuringbolts. ReconnectexhaustsystemRep.Gr.26. Installbracket-3-togetherwithcoupling rodsandgearboxselectorlever-1-. Nowfitthetwobolts-2-forbracket-3-into thegearbox. Fitgearboxselectorlever-1-ontogearbox. Pressonbothcouplingrods-arrows-.

Connectintermediatelever-4-toselector rod-5-.

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Installing gearbox

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Nowfitintermediatelever-4-ontopinof bracket. Pushonsecuringclip-3-tostop. Pressfrontselectorrod-1-ontogearbox selectorlever-2-. ThenattachairfilterRep.Gr.24. Ifnecessary,installenginecover. Reconnectearthstraptobattery. Electricalsystem;Rep.Gr.27. Note Note radio code for vehicles with coded radio. CheckgearoilChapter. AdjustselectormechanismChapter. Installinsulationtraybelowengineand gearbox,iffitted. Generalbodyrepairs,exterior;Rep.Gr.50.

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