Audi Workshop Service and Repair Manuals

Removing and installing bevel box Special tools and workshop equipment required

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

t  Socket and extended bit -T10107-

t  Extension -2024 A /1-

Removing –  Remove noise insulation → General body repairs, exterior; Rep. Gr.50.   Note Depending on version, different types of noise insulation may be fitted.

–  Remove front section of front wheel housing liner (right-side) → General body repairs, exterior; Rep. Gr.66.   Note Depending on version, different types of wheel housing liner may be fitted.

–  Remove exhaust system bracket from subframe -arrows-.

–  Disconnect exhaust system at clamp -arrows-. –  Tie up the front exhaust pipe.   Note To prevent damage, the flexible couplings in the front exhaust pipe must not be bent further than 10°.

–  If fitted, remove front left vehicle level sender -G78--arrows-.

–  Unplug electrical connector -1- at oil level and oil temperature sender -G266-.

–  Remove bolts -2- and -3-.   Note Bolt -1- can be disregarded.

–  Mark position of propshaft with flexible coupling in relation to bevel box flange. –  Unscrew propshaft with flexible coupling from bevel box flange -arrows-.   Note When slackening off bolts, counterhold propshaft flange/final drive with a suitable lever.

–  Press propshaft horizontally to rear as far as possible.   Caution t  When removing the gearbox, make sure the seal -arrow- in the propshaft flange is not damaged. If seal is damaged propshaft must be renewed. t  Slackening off bolts for pendulum support/subframe causes engine/gearbox assembly to swing forwards slightly.

–  Remove bolts -2- and -3-. –  Push the engine/gearbox assembly forward slightly and then pull the propshaft off the bevel box. –  Lift propshaft up and secure with wire.

Vehicles with 6-cylinder 3.2 ltr. engine: –  Unbolt heat shield for drive shaft (right-side) from bevel box -arrows-.

–  Unscrew bolts at bevel box -arrows 1- and at engine -arrows 2-. –  Detach bracket -A- for bevel box.

Vehicles with 4-cylinder 2.0 ltr. TFSI engine: –  Unbolt heat shield for drive shaft (right-side) from bevel box -arrows-.

–  If fitted, remove bracket for catalytic converter; to do so unscrew bolts -1- and -2-.

–  Unscrew bolts at bevel box -arrows 1- and at engine -arrows 2-. –  Detach bracket for bevel box.

Continued for all vehicles: –  Remove front right wheel. –  Unbolt drive shaft (right-side) from flange shaft on bevel box. –  Remove nuts -arrows- for swivel joint (right-side) → Running gear, front-wheel and four-wheel drive; Rep. Gr.40. –  If fitted, unscrew nut on bracket for front left vehicle level sender -G78-. –  Disengage swivel joint from wishbone.   Note Illustration shows installation position at front suspension (left-side).

–  Swivel suspension strut (right-side) outwards and support with extension -2024 A /1-, as shown in illustration.   WARNING Risk of accident if parts of support are not properly secured. Secure locking pin and wishbone with retaining clip -arrow- and nut -1-.   Note Illustration shows installation position at front suspension (left-side). –  Lift drive shaft (right-side) up and secure with wire. –  Locate subframe prior to removal, and remove together with pendulum support → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40.

–  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  Using socket and extended bit -T10107-, remove bolt securing flange shaft (right-side). To do so, screw two bolts into flange and counterhold flange shaft with suitable lever.

–  Remove bolts -arrows- securing bevel box to gearbox. –  Pull bevel box together with flange shaft (right-side) off gearbox. Installing Installation is carried out in reverse sequence; note the following: Tightening torques l  → Chapter „Exploded view - flange shafts, oil seals“. l  → Fig. „Bracket for bevel box on vehicles with 4-cylinder 2.0 ltr. TFSI engine: tightening torque and sequence“. l  → Fig. „Bracket -A- for bevel box on vehicles with 6-cylinder 3.2 ltr. engine: tightening torque and sequence“. l  → Fig. „Heat shield for drive shaft to bevel box: tightening torque“.   Note Re-attach all cable ties at the same locations when re-installing. –  Attach bevel box together with flange shaft onto gearbox (turn flange shaft when doing so).   Note Make sure you do not damage the oil seal on the gearbox. –  Secure bevel box to gearbox using 4 new bolts. –  Bolt bracket for bevel box to engine and bevel box. –  Install subframe → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40.   Note

t  The seals -arrow- in flanges of the propshaft must not be damaged when removing and installing. If seals are damaged, the propshaft must be renewed. t  Ensure propshaft is horizontal when pushing it onto guide pin.

t  Take note of the markings that were made on the propshaft and flange when removing. These must be brought into alignment again -arrows-.

–  Bolt flexible coupling on propshaft onto bevel box flange -arrows- → Rear final drive 02D, 0AV, 0BR and 0BY; Rep. Gr.39. –  Install flange shaft (right-side) → Chapter.

–  Install pendulum support → Chapter. –  Install drive shaft (right-side) → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Install exhaust system so it is free of stress → Engine, mechanics; Rep. Gr.26. –  → Chapter „Checking and topping up oil level in bevel box“.