Removal and Replacement

Bevel Box

Special tools, testers and auxiliary items required

• Used oil collection and extraction device (VAG 1782 )

• Socket and extended bit (T10107)

Removing

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

- Place the selector lever in the P position.

- Remove the right front wheel.

- Remove the noise insulation tray.

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





- Remove the right drive axle from the transmission flange.

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

- Remove the exhaust system suspended mount bolts - arrows -.





- Remove the bracket - 2 - for the oil level thermal sensor wire on the subframe.





- Remove nuts - 1 - and bolts - 2 - for the bevel box bracket.





- Remove the bracket - A - for bevel box.

- Loosen the clamping sleeve nuts - arrows - and disconnect the exhaust system.





- Use a chain to secure the exhaust system in position. To do this, insert the (3004) into the openings at vehicle floor (remove the plug, 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 bolts.





- Press the driveshaft horizontally toward the rear as far as possible.





CAUTION!
• Sealing ring - 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 pendulum support/subframe bolts, the engine/transmission assembly moves forward slightly.

- Remove the pendulum support bolts - 2 and 3 -.





- Press the engine and transmission forward slightly and remove the drive shaft from the bevel box.

- Lay the driveshaft above the bevel box and secure it against falling down.

- Remove the subframe.





For removing the subframe => Suspension,

Wheels, Steering 40 Removal and Installation. There is much useful information there. 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. In this way, the subframe can be secured and removed correctly.

- Place the (VAG 1782) beneath the transmission.

- Remove the right flange shaft bolt - arrow 1 - using the (T10107).





- Remove the four bevel box to transmission bolts.

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

Installing

Installation is performed in the reverse order of removal. Pay attention to the following:

- Place the bevel box together with the flange shaft to the transmission and rotate the flange shaft.

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

Tightening Specifications

Bevel box to transmission bolts: 30 Nm

- Position the bevel box bracket and install the nuts - 1 and 2 - hand tighten.





- Observe the installation sequence:

1. Tighten the nuts - 1 - to 3 Nm.

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

3. Tighten the nuts - 1 - to 45 Nm.

- Install the subframe.

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

- Be careful of sealing ring.





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





- Install the exhaust system tension free.

- Install the right drive axle.

- Check the oil level in the bevel box and top off. Refer to => [ Oil Filter, Changing and Oil Level, Adjusting ] 02E Transmission (Direct Shift Gearbox).

Tightening Specifications