Volkswagen Golf Service & Repair Manual: Installing gearbox

Volkswagen Golf Service & Repair Manual / 7- speed dual clutch gearbox 0CW / Gearbox mechanism, operation, contruction, diff / Removing and installing gearbox / 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

Removing gearbox

Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine Brief description ...

Specified torques for gearbox

petrol engine, 1.4 l natural gas engine: Item Bolt Nm 1, 5, 9 M12x70 80 2, 4 ...

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