Audi A3 Workshop Service and Auto Repair Manuals

Removing and installing bevel box Special tools and workshop equipment required

t  Hexagon key -V.A.G 1669-

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

Removing –  Detach air pipe leading to charge air cooler at longitudinal member (bottom right) -arrows-. –  Remove hose going to turbocharger.

–  Remove noise insulation (centre and right) -arrows-.

–  Disconnect exhaust system at clamp -arrows-. –  Tie up pipe at rear of catalytic converter to propshaft.

–  Mark position of propshaft with flexible coupling on bevel box flange. –  Unscrew propshaft with flexible coupling from bevel box flange -arrows-. –  Press front propshaft pipe slightly towards the rear.   Note

After loosening bolts -A- (⇒ following illustration N34-0712) the engine/gearbox assembly will swing slightly to the front.   Caution Make sure that the seal -arrow- in the flange of the propshaft is not damaged when removing and installing. If seals are damaged, the propshaft must be renewed.

–  First unscrew bolts -A- and then bolts -B- and remove pendulum support. –  Carefully press engine/gearbox assembly forwards. –  Unbolt drive shaft (right side) from gearbox flange shaft. –  If fitted, unbolt heat shield for drive shaft (right-side). –  If drive flange cap is fitted, pierce a hole in centre of cap using a screwdriver and lever out cap.

–  Unscrew bolt -arrow- for flange shaft (right-side) or output shaft with drive flange using hexagon key -V.A.G 1669-.

–  Remove bracket for bevel box from engine and bevel box -arrows-.   Note On vehicles with heat shield for drive shaft (right-side), three of the securing bolts are unfastened when removing heat shield. –  Place used oil collection and extraction unit -V.A.G 1782- under the vehicle. –  Tie up the drive shaft.   Note Make sure you do not damage surface coating on drive shaft. –  Remove bolts securing bevel box to gearbox. –  Detach bevel box from manual gearbox and remove bevel box. Installing Installation is carried out in reverse sequence; note the following:   Note

Always renew O-ring between bevel box and gearbox -arrow A- and seals on oil supply drillings -arrow B- and -arrow C-. Lightly oil O-ring and seals before installing. –  Push bevel box completely onto gearbox, at the same time ensuring that the bevel box input shaft splines are guided centrally onto the differential connecting piece. l  If the splines are correctly positioned and the components are located centrally, the bevel box will slide against the gearbox onto the stop.   Note Do not use the securing bolts to pull the bevel box onto the gearbox. This could cause the bevel box to tilt and the securing eyes may break off.

–  Secure bracket for bevel box with heat shield to engine and bevel box as follows: 1.  Screw in all bolts finger-tight. 2.  Pre-tighten bolts -B- and -C- to 8 Nm. 3.  Tighten bolts -A- to 25 Nm. 4.  Tighten bolts -B- and -C- to 40 Nm.

–  Secure pendulum support to gearbox with new bolts -arrows B-. –  Press engine/gearbox assembly towards bulkhead; the bevel box pin must be guided carefully into the propshaft flange when doing this.

–  Slide propshaft onto guide pin without tilting.   Caution Make sure that the seal -arrow- in the flange of the propshaft is not damaged when removing and installing. If seals are damaged, the propshaft must be renewed.

–  Secure pendulum support to subframe with new bolts -arrows A-. –  Bolt flexible coupling on propshaft onto bevel box flange → Rear final drive 02D; Rep. Gr.39. –  Bolt drive shaft (right-side) to gearbox flange → Rep. Gr.40. –  Install exhaust system free of stress → Rep. Gr.26. –  Fill up gear oil in manual gearbox with bevel box → Chapter. –  Install noise insulation panels → Rep. Gr.50. Tightening torques

Component		Nm
Bevel box to gearbox		40 + 45° 1)2)
Pendulum support to	gearbox	40 + 90° 1)3)
	subframe	20 + 90° 1)3)
Air pipe to longitudinal member		10
l  1) Renew bolts. l  2) 45° is equivalent to an eighth turn. l  3) 90° is equivalent to a quarter turn