Volkswagen Workshop Service and Repair Manuals

Removing bevel box –  Remove complete air filter housing → Rep. Gr.24. –  Remove securing clip -3- for gear selector cable from gearbox selector lever -1-.

–  Pull gear selector cable off pin. Metal relay lever –  Remove securing clip -4- for gate selector cable from relay lever -2-. –  Pull gate selector cable from pin. Plastic relay lever

Releasing cable end-piece from gate selector cable l  To avoid damage to gate selector cable, separate cable end-piece from gate selector cable before removal. –  Pull locking mechanism forward to stop in -direction of arrow 1- and then lock by turning to left in -direction of arrow 2-. –  Then push relay lever forwards (-in direction of arrow 3-). Continuation for all

–  Remove cable support bracket from gearbox -arrows-; if necessary, unclip hose -A- from bracket -B- first.

–  Remove breather pipe -arrow- from bevel box. –  Loosen wheel bolts on front left and front right. –  Raise vehicle. –  Remove front wheels. –  Remove noise insulation and lower part of front right wheel housing liner → General body repairs, exterior; Rep. Gr.66.

–  Separate exhaust system at clamp and remove exhaust system bracket from subframe -arrows-. –  Raise exhaust pipe and secure.

–  Mark position of propshaft with flexible coupling relative to bevel box flange. –  Unbolt propshaft with flexible coupling from bevel box flange -arrows-.

–  Pull connector -1- off oil level and oil temperature sender -G266-. –  If present, remove left support for exhaust manifold -A- from bevel box and exhaust manifold (bolts -2- and -3-) → Rep. Gr.26.

–  Remove bolts -2- and -3- for pendulum support on gearbox.   Note

After pendulum support securing bolts are loosened, the engine/gearbox assembly will swing slightly forwards (towards front of car). Ensure that seal -arrow- in flange of propshaft is not damaged during removal or installation. –  Press gearbox/engine assembly forward slightly and then pull propshaft out of bevel box. –  Raise propshaft and secure with wire. –  Remove left and right coupling rods from anti-roll bar.

–  Unscrew nuts -arrows- for swivel joint and suspension links. –  Remove steering box from subframe, raise and secure. –  Fix position of subframe prior to removal → Running gear, axles, steering; Rep. Gr.40. –  Remove subframe with pendulum support, anti-roll bar, brackets and suspension links → Running gear, axles, steering; Rep. Gr.40.

–  If present, remove shield for right drive shaft from bevel box -arrows-. –  Remove right drive shaft from flange shaft of gearbox. Secure drive shaft to body using wire, taking care not to damaged surface protection.

–  Remove bevel box carrier bolts from bevel box -arrows 1- and engine -arrows 2-. –  Remove bevel box carrier.

–  Remove right support -A- for exhaust manifold -arrows- → Rep. Gr.26.

–  Remove right flange shaft bolt with socket -T10107 A--arrow 1-.   Note Right flange shaft remains in bevel box.

–  Remove lower securing bolts -arrows- for joining bevel box to gearbox.

–  Remove upper securing bolts for joining bevel box to gearbox. A heat shield -arrow A- is attached to top of bevel box. Bolt -arrow B- is accessible from beneath heat shield. Bolt -arrow C- is accessible from above heat shield. –  Carefully press bevel box off gearbox, taking care that it does not fall. –  Remove bevel box.

–  If bevel box is to be renewed, remove heat shield -A--arrows-.