Transfer Case: Service and Repair
Bevel Box
Special tools, testers and auxiliary items required
• Oil Collecting and Extracting Device (V.A.G 1782)
• Socket and Extended Bit (T10107)
• Bracket (2024 A /1)
Removing
- Remove the noise insulation.
• Depending on the version, different noise insulation may be installed.
- Remove the front section of the right wheel housing liner.
• Depending on the version, different wheel housing liner may be installed.
- Remove the holder for the exhaust system from the aggregate holder - arrows -.
- Separate the exhaust system at the clamping sleeve - arrows -.
- Tie up the exhaust pipe.
• To prevent damage, the decoupling element on the front exhaust pipe must never be angled more than 10°.
- If installed, remove left front level control system sensor (G78) - arrows -.
- Disconnect the connector - 1 - on the oil level thermal sensor (G266).
- Remove the bolts - 2 - and - 3 -.
• Ignore bolt - 1 -.
- Mark the position of driveshaft with flexible disc to bevel box flange.
- Remove the driveshaft and flexible disc from the bevel box flange shaft - arrows -.
• In order to loosen the bolts, hold a lever against the driveshaft flange/final drive.
- Slide front driveshaft tube as far back as possible.
• Sealing ring - arrow - in driveshaft flange must not be damaged when removing transmission. If seal is damaged, driveshaft must be replaced.
• When loosening pedal support/subframe bolts, engine/transmission assembly moves forward slightly.
- Remove the bolts - 2 - and - 3 -.
- Push the aggregate forward slightly and remove the driveshaft from the bevel box.
- Lift up driveshaft and secure with wire.
Vehicles with 6-Cylinder 3.2L Engine
- Remove the right drive axle heat shield from bevel box - arrows -.
- Remove the bolts on the bevel box - 1 - and engine - 2 -.
- Remove the bevel box bracket - A -.
4-Cylinder 2.0L TFSI Vehicles
- Remove the right drive axle heat shield from bevel box - arrows -.
- Remove the catalytic converter support by removing the bolts - 1 - and - 2 - if applicable.
- Remove the bolts on the bevel box - arrows 1 - and engine - arrows 2 -.
- Remove the bevel box bracket.
All Vehicles
- Remove the right front wheel.
- Remove the right drive axle from the flange shaft on the bevel box.
- Remove the bolt - arrow - for the right ball joint.
- If equipped, remove the left front level control system sensor nuts.
- Remove the ball joint from the control arm.
• The installation position on the left front wheel suspension is shown in the illustration.
- Move the right suspension strut to the outside and support it with the (2024 A /1) as illustrated.
There is the risk of an accident due to loose support parts.
• Secure the securing pin and control arm with the plug connector - arrow - and nut - 1 -.
• The installation position on the left front wheel suspension is shown in the illustration.
- Lift up right drive axle and secure with wire.
- Tighten the subframe crossmember before removing.
- Place the (V.A.G 1782) under the transmission.
- Remove right flange shaft bolt with (T10107) by installing 2 bolts in flange and counter holding flange shaft with assembly lever.
- Remove the bevel box bolts - arrows - on the transmission.
- Remove bevel box from transmission together with right flange shaft.
Installing
Install in reverse order, paying attention to the following:
Tightening Specifications
• Refer to => [ Flange Shafts, Shaft Seals Overview ] 02EA Transmission.
• Bevel box bracket for vehicles with four-cylinder, 2.0L TFSI - Tightening specification and sequence" => [ Bevel Box Bracket for Vehicles with 4-Cylinder, 2.0L TFSI - Tightening Specification and Sequence ] 02EA Transmission.
• Bevel box bracket for vehicles with six-cylinder, 3.2L engine => [ Bevel Box Bracket for Vehicles with 6-Cylinder 3.2L Engine - Tightening Specification and Sequence ] 02EA Transmission.
• Refer to => [ Heat Shield for Drive Axle on Bevel Box - Tightening Specifications ] 02EA Transmission.
• When installing, bring all cable ties back to same positions.
- Place bevel box together with flange shaft on transmission and rotate flange shaft.
• Make sure the sealing ring on the transmission is not damaged.
- Attach bevel box to transmission with four new bolts.
- Attach the bracket to the engine and the bevel box.
- Install the subframe.
• Sealing ring - arrow - in driveshaft flanges must not be damaged when removing and installing. If seal is damaged, driveshaft must be replaced.
• Slip driveshaft horizontally onto respective guide pin.
• During removal, pay attention to the markings on the driveshaft and flange. These must be aligned with each other - arrows -.
- Secure the driveshaft with flexible disc on the bevel box flange - arrows -.
- Install the right flange shaft. Refer to => [ Right Flange Shaft ] Right Flange Shaft.
- Install pendulum support. Refer to => [ Subframe Mount Overview ] Description and Operation.
- Install the right drive axle.
- Install the exhaust system free of tension.
- Refer to => [ Oil Level in Bevel Box, Checking and Topping Off ] Oil Level In Bevel Box, Checking and Topping Off.