Volkswagen Workshop Service and Repair Manuals

Removing and installing bevel box Special tools and workshop equipment required

t  Socket -V.A.G 1669-

t  Torque wrench -V.A.G 1332- t  Drip tray Additional required information t  Workshop Manual Golf 1998 ►, Bora 1999 ► Engine, mechanics t  Workshop Manual Golf 1998 ►, Bora 1999 ►, Running gear, axles, steering - front and four-wheel drive Removing –  Mark position of propshaft with flexible coupling relative to bevel box flange.

–  Unbolt propshaft with flexible coupling from bevel box flange -arrows-. –  Disconnect right drive shaft from gearbox. –  Raise drive shaft as high as possible and secure. Take care not to damage paint on drive shaft in the process. –  If a cap is fitted, remove it by piercing cap centre with a screwdriver and levering out. –  Remove right output shaft bolt or right flange shaft bolt using socket -V.A.G 1669- or commercially available 6 mm socket. –  Separate exhaust system at double clamp → Rep. Gr.26.

–  Remove pendulum support from subframe -arrows A-. –  Carefully press engine and gearbox forwards. –  Carefully pull front propshaft off centring pin.   Note Do not damage seal in the propshaft flange during removal or installation. –  Place drip tray under gearbox and engine.

–  Unbolt turbocharger oil return line -arrow- from engine → Rep. Gr.21. –  Drain gear oil from bevel box.

–  Remove bevel box carrier from engine and bevel box -arrows-. –  Remove bevel box/gearbox connecting bolts. –  Press bevel box off gearbox. –  Remove bevel box. Installing Install in the reverse order of removal, observing the following:   Note

t  Always renew O-ring for sealing bevel box and gearbox -arrow A- and oil seals for sealing holes for oil supply system -arrows B and C-, lightly coating with oil. t  Push bevel box completely onto gearbox, ensuring that splines of bevel box input shaft are guided centrally onto differential connecting piece. t  Also bring splines of right flange shaft or drive flange with output shaft into alignment. t  If the position of the splines and the centre guide are correct, then the bevel box will slide on to stop against the gearbox. Turn left drive shaft slightly if necessary. t  Do not use securing bolts to pull bevel box onto gearbox, or bevel box will cant and bolt holes can break off. t  When removing and installing, do not damage seals in propshaft flanges. t  Renew propshaft if damaged. t  Ensure that propshaft is horizontal when pushing onto centring pin. t  Renew seal for drive shaft, if present → Running gear, axles, steering - front and four-wheel drive; Rep. Gr.40. t  Join exhaust pipe at double clamp → Rep. Gr.26. t  Unbolt turbocharger oil return line from engine → Rep. Gr.21. t  Checking gear oil in manual gearbox with bevel box → Chapter. Installing bevel box/engine carrier free of tension.

When installing bevel box carrier, observe following sequence: –  Screw in all bolts hand-tight. –  Tighten bolts -B- and -C- first to 10 Nm. –  Tighten bolts -A- to 25 Nm. –  Tighten bolts -B- and -C- to 40 Nm. Torque settings

Bevel box to gearbox

40 Nm + 45°

Flexible joint with heat shield to bevel box flange → Item. Drive shaft to flange shaft → Running gear, axles, steering - front and four-wheel drive; Rep. Gr.40.