Volkswagen Workshop Service and Repair Manuals

Removing and installing bevel box , Passat 2011 ► with 3.6 l V6 engine Special tools and workshop equipment required

t  Tensioning strap -T10038-

t  Socket -T10107 A- Removing: –  Raise vehicle. All 4 supports of lifting platform must be at same height. –  Move selector lever to position »P« position. –  Remove noise insulation → General body repairs, exterior; Rep. gr.66. –  Unbolt right drive shaft from gearbox → Rep. gr.40.

–  Secure drive shaft to suspension strut with tensioning belt -T10038-. –  Remove pendulum support → Rep. gr.40

–  Remove exhaust system bracket from subframe -arrows- → Rep. gr.26.

–  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 to stop.

The -seal- in the propshaft must not be damaged.

–  Remove heat shield above right drive shaft -1- → Rep. gr.40.

–  Remove bracket -A- between engine and bevel box. First remove bolt -1-.

–  Remove counter-sunk bolt using insert -T10107 A-. Flange shaft remains in bevel box.

–  Unbolt bevel box from gearbox -arrows- and remove it. To remove bevel box, push engine forwards slightly (second mechanic). Installing Install in reverse order of removal. During this step, observe the following: –  Push bevel box together with flange shaft onto gearbox and turn flange shaft while doing so. –  Bolt bevel box onto gearbox using 4 new bolts. Torque setting 40 Nm

–  Screw in bolts -1- and -2- hand-tight. –  Observe assembly order: 1 -  First tighten bolts -1- to 3 Nm. 2 -  Tighten bolts -2- to 40 Nm. 3 -  Finally tighten bolts -1- to 40 Nm.

–  Install counter-sunk bolt using insert -T10107 A-. Torque setting 30 Nm

–  Install heat shield above right drive shaft -1- → Rep. gr.40. –  Bolt right drive shaft to gearbox → Rep. gr.40. –  Install pendulum support → Rep. gr.40. –  Bolt propshaft to bevel box -arrows- → Rep. gr.39. –  Bolt exhaust system bracket to subframe -arrows- → Rep. gr.26. Continue installation in reverse order of removal.