Bevel Box

Bevel Box

Special tools, testers and auxiliary items required

• Used Oil Collecting and Extracting Device (V.A.G 1782)

• Socket and Extended Bit (T10107)

• Hooks (3004)

Removing

- Move the selector lever into the "P" position.

- Lift the vehicle, all 4 lift points of the hoist must be at the same height.

- Remove the right front wheel.

- Remove the noise insulation.

- Remove the right drive heat shield bolts - arrows - and shield from the bevel box.






- Disconnect the right drive axle from the transmission flange.

- Lift up the right drive axle and secure with wire.

- Remove the exhaust system suspended mount bracket bolts - arrows - from the subframe.






- Remove the bracket - 2 - for the oil level thermal sensor (G266) wire from the subframe.






- Remove the bracket bolts - 1 and 2 -.






- Remove the bracket - A - from between the bevel box and transmission.

- Disconnect the exhaust system.






- Tie up the exhaust system with a chain. To do this, insert the hooks (3004) into the openings at the vehicle floor (remove the plugs, if necessary).






- Identify the position of the driveshaft flexible disc and bevel box flange to each other.

- Remove the driveshaft flexible disc to bevel box flange bolts - arrows -.






- Push the final drive horizontally as far as possible to the rear.







• The seal - arrow - in the driveshaft flange must not be damaged when removing the transmission. If the seal is damaged, the driveshaft must be replaced.

• When loosening the pendulum support/subframe bolts, the engine/transmission assembly moves forward slightly.

- Remove the bolts - 2 and 3 -.






- Press the engine/transmission assembly forward slightly and remove the driveshaft from the bevel box.

- Place the driveshaft above the bevel box and secure it from falling.

- Remove the subframe.






When removing the subframe. If done correctly, the subframe can be removed and installed without the customer experiencing increased tire wear later. It is recommended to read this information prior to removing the transmission. This way, the subframe can be secured and removed correctly.

- Place the used oil collecting and extracting device (V.A.G 1782) under the transmission.

- Remove the right flange shaft bolt - arrow 1 - using the socket and extended bit (T10107). Tightening specification. Refer to => [ Flange Shaft and Bevel Box Seals Overview ] Description and Operation.






- Remove the four bevel box bolts from the transmission.

- Remove the bevel box from the transmission together with the flange shaft.

Installing

Install in reverse order of removal. Pay attention to the following:

- Place the bevel box on the transmission together with the flange shaft while turning the shaft.

- Secure the bevel box to the transmission with 4 new bolts.

Tightening Specification:

40 Nm

- Install the bracket bolts - 1 and 2 - hand tight.






- Follow the installation sequence:

1. First, tighten the bolts - 1 - to 3 Nm.

2. Tighten the bolts - 2 - to 35 Nm.

3. Then, tighten the bolts - 1 - to 45 Nm.


- Install the subframe.
- Press the engine/transmission toward the bulkhead; while doing so, carefully guide the pin of bevel box into the driveshaft flange.

- Be careful of the seal.






- Secure the pendulum support to the transmission with new bolts - 2 and 3 -.






- Install the exhaust system without tension.

- Install the right drive axle.

- Check oil level in the bevel box and fill if necessary. Refer to => [ Bevel Box Gear Oil Level, Checking and Filling ] Service and Repair.

Tightening Specifications