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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Passat B5 (from 1996 to 2004, the year of issue)

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Volkswagen Passat B5
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Passat B5
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Installing gearbox



Location and torque bolts gearbox models with four-cylinder engine

POSITION
BOLT
Tightening torque
1
M12h75
65 Nm
2
M12h110
65 Nm
3
M12h90
65 Nm
4
M12h67
65 Nm
5
M10h135
45 Nm
6
M10h45
45 Nm
A
Guide bushings

Location and torque bolts gearbox models with five-cylinder engine

POSITION
BOLT
Tightening torque
1
M12h75
65 Nm
2
M12h130
65 Nm
3
M12h45
45 Nm
4
M12h70
45 Nm
5
M10h60
45 Nm
6
M10h80
65 Nm
A
Guide bushings

Location and torque bolts transmission on models with six-cylinder engine

POSITION
BOLT
Tightening torque
1
M12h97
65 Nm
2
M12h90
65 Nm
3
M12h80
65 Nm
4
M12h45
45 Nm
5
M10h135
65 Nm
A
Guide bushings

Location and torque mounting bolts gearbox

POSITION
BOLT
Tightening torque
1
M10h30
40 Nm
2
M10h35
40 Nm
3
M8h20
20 Nm

A warning

The gearbox housing can be manufactured as aluminum and magnesium alloy. If the gearbox housing is made of magnesium alloy around the oil drain plug inscription Mg Al 9 Zn 1. If the vehicle is established Transmission of magnesium alloy, it is necessary to coordinate all the details of which are connected to a transmission, including the transmission mounting bolts that They should be covered with a special protective layer. If you do not agree on the details of which are connected to the gearbox housing made of magnesium alloy, the housing can be exposed to corrosion.


PERFORMANCE ORDER
1. Check the condition of the clutch.
2. Clean the spline part of the primary shaft of the gearbox and grease with a thin layer of special lubricants based on molybdenum disulfide.
A warning

A lubricant layer should be thin and uniform, as otherwise when the clutch is excessive lubricant dropped on the clutch surface, which can disrupt its operation.


3. Apply a thin stand of lubricant on the basis of molybdenum disulphide on the head of the pusher mating clutch lever.
4. Check that the engine block mounted guides for centering the gearbox.
5. Lift the transmission to the engine and set the clutch slave cylinder.
6. Move the transmission to the engine, and the transmission input shaft should enter into grooves clutch. To align the splines of transmission input shaft splines clutch may have slightly crank the engine. When installing the gearbox input shaft should not hang on a disc clutch.
7. Move transmission forward to clutch installed on a cylinder sleeve.
8. Insert the bolts securing the gearbox to the engine, and at this stage tighten bolts the gearbox 25 Nm.
9. Install the starter.
10. Tighten the transmission to the engine torque.
11. Connect the ground bus to the gearbox.
12. Screw and tighten in the sequence 1, 2, 3 mounting bolts gearbox, see. Fig. Arrangement and the moments of a tightening of bolts of fastening of support of a transmission.
13. Remove tool for raising the transmission.
14. Connect to a transmission drive shafts.
15. Install the protective covers of power shafts and secure them with bolts, having tightened their moment of 20 Nm.
16. Install and tighten the gearbox control rod 20 Nm and the shift rod 40 Nm.
17. Connect the transmission electrical connectors tachometer and the reverse gear.
18. Establish a reception exhaust pipe.
19. Reinstall the expansion tank.
20. Install the air tube from the air flow meter and secure it with clamps.
21. Connect the ground cable to the battery.
22. Check and, if necessary, bring the oil level in the gearbox.
23. Install the top casing of the engine.
24. Establish the bottom mudguard of the engine.




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