Installing gearbox

Install in reverse order of removal, observing the following:

Renew bolts which are tightened by turning through a specified angle.

Renew self-locking nuts and bolts, and seals, O-rings and gaskets.

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.

In some vehicles, a cover is fitted over the engaging levers.

The cover prevents dirt getting in.

Specified torque: 8 N·m

Only Polo with petrol engine:

• Remove right flange shaft.

• 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:

• Renew needle bearing -arrow- in crankshaft → Rep. gr.13.

• 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.

• 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.

• Remove both plugs from breathers -arrows- and install breather caps (renew if necessary).

• Bolt cable support bracket -1- to gearbox.

Install left assembly mounting as follows:

• Always renew all bolts on left assembly mountings.

Golf, Golf Estate:

• Bolt gearbox bracket -1- to gearbox.

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

Polo:

• Bolt gearbox bracket to 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.

• 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.

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