Audi Workshop Service and Repair Manuals

Dismantling and assembling bevel box

Special tools and workshop equipment required

t	Fitting tool -VW 204 B-

t	Press tool -40-21-

t	Gearbox support -3221-

t	Support plate -3221/1 A -

t	Torque wrench -V.A.G 1601-

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 408 A-

t	Tube -VW 415 A-

t	Torque wrench -V.A.G 1331-

t	Support rails -VW 457-

t	Press tool -VW 412-

t	Puller -V.A.G 1582-

t	Adapter -V.A.G 1582/1-

t	Press tool -VW 473-

t	Thrust plate -VW 447 H-

t	Fitting tool -VW 191-

t	Thrust piece -2050-

t	Tube -VW 460/2-

t	Press tool -VW 454-

t	-1-Internal puller -Kukko 21/3-, -Kukko 21/7-, -Kukko 21/8-

t	-3-Splitter -Kukko 17/2-

t	-4-Counter-support -Kukko 22/1-, -Kukko 22/2-

t	Thrust pieces for pinion shaft bearing -VW 470-

t	Thrust pad -VW 512-

t	Tube -VW 771/33-

t	Drift sleeve -40-20-

t	Extension -3161-

t	Puller -T10037-

t  Used oil collection and extraction unit -V.A.G 1782-

Dismantling –  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Drain gear oil. –  Secure bevel box in gearbox support.   Note If the output flange hexagon nut is not to be loosened, then the bevel box can be held in gearbox support -2004- for dismantling and assembling.

–  Remove hexagon nut for output flange. A -  Socket attachment with 3/4" drive –  Remove output flange. –  Pry out oil seal using screwdriver. –  Remove small tapered roller bearing inner race for shaft bevel gear.

–  Remove pinion housing -1-; to do so, screw hexagon bolts -arrows- in evenly so that pinion housing does not cant.   Note The pinion housing can also be removed and installed with the output flange fitted. –  Remove shim “S3”.

–  Press small tapered roller bearing outer race out of pinion housing. A -  Internal puller 46 ... 58 mm -Kukko 21/7-

–  Pull large tapered roller bearing outer race out of pinion housing. A -  Internal puller 46 ... 58 mm -Kukko 21/7- B -  Counter-support -Kukko 22/2- –  Remove shaft bevel gear with shim “S4” and spacer ring.

–  Pull off large tapered roller bearing inner race from shaft bevel gear; to do so, fit adapter and apply tension behind the bearing rollers. –  Then turn bearing and retighten adapter.

–  Bolt puller -T10037- to flange shaft (right-side)/drive flange (right-side). –  Use knurled nut -T10037/1- and lower support -A- to align puller parallel with flange shaft/drive flange. –  Pull out flange shaft/drive flange. –  If the oil seal has to be renewed then it must be levered out now.

–  Press off drive flange from output shaft.

–  Remove cover, when doing this screw hexagon bolts -A- in evenly so that the cover does not cant.

–  Press large tapered roller bearing outer race out of cover. A -  Internal puller 56 ... 70 mm -Kukko 21/8- –  Remove bevel gear with input shaft.

–  Press off large tapered roller bearing inner race from bevel gear. A -  Splitter 22 ... 115 mm -Kukko 17/2-

–  Press off small tapered roller bearing inner race from input shaft. A -  Splitter 22 ... 115 mm -Kukko 17/2-   Note Inner race can also be pulled off using tapered roller bearing puller -V.A.G 1582- and adapter -V.A.G 1582/3- but first place thrust plate -40-105- on input shaft.

–  Press small tapered roller bearing outer race out of final drive housing. A -  Internal puller 46 ... 58 mm -Kukko 21/7-

–  Remove circlip for roller bearing from final drive housing: lever one end of circlip out of groove by turning screwdriver -A- . –  Lift this end of circlip using screwdriver -B- and lever out circlip further by re-applying screwdriver.

–  Pull roller sleeve out of final drive housing. A -  Counter-support -Kukko 22/1- B -  Internal puller 13 ... 23 mm -Kukko 21/3-

Assembling   Note Table of adjustments → Anchor. –  Carefully press roller bearing into final drive housing as far as stop. l  The marking faces towards press tool. –  Fit new circlip in final drive housing.

–  Fit shim “S2” and press small tapered roller bearing outer race into final drive housing.   Note Interrupt pressing operation as soon as possible to allow the tube -VW 771/33- to be seated over the complete circumference of the outer race.

–  Press small tapered roller bearing inner race onto input shaft.

–  Press large tapered roller bearing inner race onto bevel gear. –  Insert bevel gear with input shaft into final drive housing.

–  Fit shim “S1” into cover and press in large tapered roller bearing outer race. –  Install cover with new O-ring.   Note Keep straight when installing, tighten securing bolts diagonally and in stages

–  Press large tapered roller bearing inner race onto shaft bevel gear. –  Insert shaft bevel gear with shim “S4” and spacer ring into final drive housing. l  Chamfer on spacer ring faces shaft bevel gear.

–  Press small tapered roller bearing outer race into pinion housing.

–  Press large tapered roller bearing outer race into pinion housing. –  Fit shim “S3” onto final drive housing. –  Install pinion housing with new O-ring.   Note t  Keep straight when installing, screw in and tighten securing bolts diagonally and in stages t  The pinion housing can also be removed and installed with the output flange fitted. –  Insert small tapered roller bearing inner race for shaft bevel gear.

–  Drive in new oil seal for output flange until flush. –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-. –  Install output flange. l  The threads of the hexagon nut for the output flange and the shaft bevel gear must be clean.

–  Tighten hexagon nut for output flange. A -  Socket attachment with 3/4" drive –  Drive in new oil seal for flange shaft/drive flange with output shaft as far as stop → Chapter. –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-.

–  Press drive flange onto output shaft. –  Carefully drive in flange shaft/drive flange with output shaft (while turning). –  Secure flange shaft/drive flange with output shaft → Chapter. –  Renew drive flange cap, if fitted.