Volkswagen Workshop Service and Repair Manuals

Removing bevel box –  Remove noise insulation below engine and gearbox. → General body repairs, exterior; Rep. gr.50.

–  To gain more clearance in vehicles with supplementary heaters, remove coolant hoses -1- and -2- for supplementary heater from engine and body. Do not open pipes → Auxiliary heater; Rep. gr.82.

–  Remove drive shaft heat shield, if present, from bevel box (2 nuts -arrows-) → Running gear, axles, steering; Rep. gr.40. –  Remove right drive shaft → Running gear, axles, steering; Rep. gr.40.

–  Mark position of propshaft with flexible coupling relative to bevel box flange with paint. –  Unbolt propshaft from bevel box -arrows- → Rep. gr.39. –  Push front propshaft tube back to stop. –  Place a cloth on subframe to avoid damaging paint of propshaft when it is placed on subframe. –  Put propshaft down on subframe.

–  Remove engine cover. –  Remove particulate filter -A- from upper part of engine -arrows- → Rep. gr.26. –  Remove bottom particulate filter from engine and detach particulate filter support → Rep. gr.26. –  Secure it to front wall of plenum chamber.

–  Remove exhaust system bracket from subframe -arrows-.

–  Remove pendulum support from gearbox, bolt -1- and bolt -2-.

–  Press engine/gearbox towards front end; support it using pendulum support as shown. -A- = Collar bolt M10 x 35

–  Drain oil from bevel box using bolt -A-. –  Then screw in new bolt and tighten to 15 Nm. –  Remove securing bolt for right flange shaft -arrow- with socket. To do this, screw 2 bolts into flange and counterhold flange with lever.

–  Bolt puller -T10037- to right flange shaft.   Note To remove right flange shaft, use puller -T10037- to avoid damage to bearing of flange shaft. –  If necessary, lay a spacer (e.g. press piece -VW 434-) between bevel box carrier and knurled nut -T10371/1-. –  Use spindle-A- to align puller parallel to flange. –  Pull out right flange shaft.

–  Seal bevel box with cap -T10460-.

–  Remove turbocharger support -arrow-. → Rep. gr.21 –  Remove bevel box carrier bolts from engine and bevel box -A- and -B-. –  Remove bevel box carrier.

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

–  Remove lower securing bolts -arrows- for joining bevel box to gearbox. –  Carefully press bevel box off gearbox and remove.