Bevel Box, Removing and Installing

Bevel box, removing and installing

Special tools, testers and auxiliary items required
^ Drip tray V.A.G1306
^ Hex socket T10107
^ Puller T10037

Removing





Note:
^ Read rules for cleanliness when working on the transmission.
^ General repair instructions.





- Remove center sound insulation tray fasteners - 1...3-





- Remove sound insulation (right side) - arrows-.
- Remove right axle shaft





- Unbolt heat shield for axle shaft (right side) from bevel box.
- Place drip tray V.A.G1 306 under transmission.





- Remove bolt for flange shaft (right side) arrow1 - using hex key T10107. (Bolt must be replaced).





-Remove flange shaft using puller T10037
-Remove front right wheel.





- Remove bolts - 1 - and - 2 - at bracket for bevel box.
- Remove bracket -A - for bevel box.





- Disconnect exhaust system at clamp - arrows
- Push clamp toward rear.





- Tie up exhaust system with a chain. To do so, engage hooks 3004 in openings on underbody (if necessary remove plugs).

Note:
^ The flexible pipe connection (de-coupling element) of the exhaust system must not be bent more than 10° - otherwise it can be damaged.

- Mark relationship of driveshaft and flexible coupling to bevel box flange with a colored marker.





- Unscrew driveshaft with flexible coupling from bevel box flange - arrows

Note: When loosening bolts, counterhold driveshaft flange/final drive with a suitable lever.





- Press driveshaft horizontally to rear as far as possible.

Caution:
^ When removing the driveshaft, make sure the seal in the driveshaft flange is not damaged. If the seal is damaged the driveshaft must be replaced.
^ Loosening bolts for the pendulum support1subframe causes the engine/transmission assembly to swing forward slightly.





- Remove bolts - A - and then bolts - B - on pendulum support.
- Remove pendulum support.
- Push engine/transmission assembly forward slightly and then pull driveshaft off bevel box.
- Place driveshaft above bevel box and secure to prevent it from falling.
- Prevent bevel box from falling by supporting it from below, e.g. with engine/transmission jack V.A.G1383 A. A second technician may be required to hold bevel box.

Caution: There is a risk of the bevel box failing out once the four securing bolts are removed.

- Remove 4 securing bolts for bevel box at transmission.
- Separate bevel box from transmission.

Installing
Perform installation in reverse sequence of removal. Note the following:

Note: All cable ties which are released or cut open during removal must be replaced in the same position when installing.

- Secure bevel box to transmission using 4 new bolts.
- Insert flange shaft into bevel box (turn flange shaft when doing so).

Note: Make sure the flange shaft is kept straight to avoid any damage to the seal in the transmission.

- Secure flange shaft using new countersunk bolt.





- Install bracket - A - for bevel box, noting following assembly sequence:

1. First tighten bolts - 1 - to 3 Nm.
2. Tighten bolts - 2 - to 35 Nm.
3.Then tighten bolts - 1 - to 45 Nm.

- Press engine/transmission assembly toward bulkhead. Bevel box pin must be guided carefully into driveshaft flange when doing this.





Note:
^ When removing and installing, do not damage seals in driveshaft flanges. If seals are damaged, the driveshaft must be replaced.
^ Push driveshaft horizontally onto guide pin:





- Install pendulum support, using new bolts - arrows A and - arrows B -> - 34-3, Pendulum support, removing and installing.





- Bolt driveshaft with flexible coupling to bevel box flange - arrows-:





Note: Take note of the markings that were made on the driveshaft and flange when removing. These must align with each other again - arrows-.

- Assemble exhaust system.

- Install right axle shaft

- Install heat shield for axle shaft onto bevel box.
Checking oil level in bevel box -> 34-4, Bevel box gear oil checking and topping up.





Tightening torques
Component Nm
Flange shaft to transmission (countersunk bolt), 30
always replace bolt
Bevel box to transmission 40 Nm + 90° further
4 x bolts (90° is equivalent to a one quarter turn)
always replace bolts
Heat shield for axle shaft 25