Volkswagen Workshop Service and Repair Manuals

Removing bevel box

Check whether a breather pipe -arrow- is installed in bevel box. –  To do this, it may be necessary to remove complete air filter housing → Rep. gr.23. To remove breather pipe, first remove selector mechanism from gearbox:

–  Remove securing clip -3- for gear selector cable from gearbox selector lever -1- and pull cable off pin -arrow-. Metal relay lever –  Remove securing clip -4- for gate selector cable from relay lever -2- and pull cable off pin -arrow-. Plastic relay lever

Releasing cable end-piece from gate selector cable l  To avoid damaging the gate selector cable, it is necessary to disconnect the cable end-piece from the gate selector cable –  Pull locking mechanism forward to stop in -direction of arrow 1- and then lock by turning to left in -direction of arrow 2-. –  Then push relay lever forwards (-in direction of arrow 3-). Continuation for all

–  The cable support bracket is secured with either 2 bolts and a flange nut -arrows-,

or with 3 bolts -arrows-.

–  Remove breather pipe -arrow- from bevel box. –  Raise vehicle. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50.

–  Separate exhaust system at clamp and remove exhaust system bracket from subframe -arrows-.

–  Separate exhaust system at clamp -arrows-. –  Raise exhaust pipe and secure.

–  Mark position of propshaft with flexible coupling relative to bevel box flange. –  Unbolt propshaft with flexible coupling from bevel box flange -arrows-.

–  Pull connector -1- off oil level and oil temperature sender -G266-.

–  Remove pendulum support from gearbox.   Note

After pendulum support securing bolts are loosened, the engine/gearbox assembly will swing slightly forwards (towards front of car). Ensure that seal -arrow- in flange of propshaft is not damaged during removal or installation. –  Press gearbox/engine assembly forward slightly and then pull propshaft out of bevel box. –  Raise propshaft and secure. –  Remove left and right coupling rods from anti-roll bar.

–  Unscrew nuts -arrows- for swivel joint on suspension links. –  Remove steering box from subframe, raise and secure. –  Fix position of subframe prior to removal → Running gear, axles, steering; Rep. gr.40. –  Remove subframe with pendulum support, anti-roll bar, brackets and suspension links → Running gear, axles, steering; Rep. gr.40.

–  If present, remove heat shield for right drive shaft from bevel box -arrows-. –  Remove right drive shaft from gearbox flange shaft. –  Secure drive shaft, taking care not to damage surface protection. Vehicles with turbo diesel engine

–  Unbolt turbocharger oil return line -A- from engine → Rep. gr.21. –  Remove bevel box carrier bolts from engine and bevel box -arrows 1- and -arrows 2-. –  Remove bevel box carrier.

–  Remove support -A- for exhaust manifold, if present → Rep. gr.26. Vehicles with 6-cylinder petrol engine

–  Remove bolts -arrows- for bevel box carrier from engine and bevel box. –  Remove gearbox carrier. Continuation for all

–  Remove right flange shaft bolt with socket-arrow 1-.   Note Right flange shaft remains in bevel box.

–  Remove lower securing bolts -arrows- for joining bevel box to gearbox.

–  Remove upper securing bolts for joining bevel box to gearbox. A heat shield -arrow A- is installed on top of bevel box in some vehicles. Bolt -arrow B- is accessible from beneath heat shield. Bolt -arrow C- is accessible from above heat shield. –  Carefully press bevel box off gearbox, taking care that it does not fall. –  Remove bevel box.

–  If bevel box is to be renewed, remove heat shield -A--arrows-.