Audi Workshop Service and Repair Manuals

Assembling bevel box   Note Table of adjustments → Chapter.

Pressing in oil supply sleeves –  Carefully press in until stop.   Note t  Installation position: end with marking faces press tool t  Sleeves can also be driven in with press tool -VW 409- with the bevel box remaining assembled.

Pressing roller bearing into final drive housing –  Carefully press roller bearing into final drive housing onto stop using sleeve -V.A.G 30-21-   Note The marking faces towards press tool.

–  Press large tapered roller bearing inner race onto bevel gear.

–  Fit oil deflector plate with recess -arrow A- onto lug -arrow B- in large cover.   Note On some gearboxes shim S1 is fitted between oil deflector plate and large cover. If fitted, place shim at the same position when installing.

–  Insert shim S1 into large cover and press in large tapered roller bearing outer race.

–  Insert bevel gear with input shaft -1- into final drive housing. –  Lubricate new O-ring with oil and fit onto large cover -2-.   Note The O-ring is not fitted on all gearboxes. On gearboxes without O-ring, apply sealant -AMV 188 200- evenly to sealing surface. –  Fit cover and tighten bolts -3-, -4- and -5- diagonally and in stages to correct torque → Item.

–  Turn bevel box in assembly stand by 180°. –  Fit tapered roller bearing inner race -A- onto bevel gear with input shaft as far as stop. –  Then place tapered roller bearing outer race -B- and shim S2-C- on top. –  Fit a new O-ring -arrow- onto sealing surface of small cover -D-. –  Insert small cover and tighten bolts -E- to torque → Item.

–  Press in outer race for small tapered roller bearing into pinion housing. Make sure that the lug -arrow- on pinion housing does not make contact with thrust plate -VW 402- when pressing in.

–  Press large tapered roller bearing outer race into pinion housing. –  Insert shaft bevel gear with shim S4 and inner race for large tapered roller bearing in final drive housing. –  Apply sealant to both sides of shim S3 and to final drive housing.

–  Install pinion housing -1- (apply sealant to bolts when fitting). –  Insert small tapered roller bearing inner race for shaft bevel gear. –  Drive in new oil seal for output flange as far as stop using thrust piece -T10049-. –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-. –  Apply multi-purpose grease evenly to splines of output flange and shaft bevel gear.

Drawing in output flange A -  Two-arm puller, e.g. -Kukko 20/10- –  Attach hooks to underside of pinion housing. –  Coat threads of new hexagon nut and shaft bevel gear with locking fluid -D 000 600-. –  Install new hexagon nut for output flange and tighten to specified torque → Item.

Socket -A- for 3/4" drive

–  Drive in new oil seal for flange shaft (right-side) as far as stop. –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-.

–  Carefully press in flange shaft (right-side) while turning. –  Check whether it is still possible to turn flange shaft after pressing in. –  If necessary, apply a blow with a plastic-headed hammer onto other end of flange shaft.