Volkswagen Workshop Service and Repair Manuals

Removing bevel box

Bevel box with breather pipe -arrow- –  If necessary, 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-).

–  Remove cable support bracket from gearbox -arrows-, lay to side and secure with wire.

–  Remove breather pipe -arrow- from bevel box. Continuation for all –  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. –  Fix position of subframe prior to removal → Running gear, axles, steering; Rep. gr.40. –  Remove subframe → Running gear, axles, steering; Rep. gr.40.

–  Remove support -A- for exhaust manifold, if present → Rep. gr.26.

–  If present, remove heat shield for right drive shaft from bevel box -arrows-. Heat shield is secured on some engines with 2 nuts. –  Remove right drive shaft → Running gear, axles, steering; Rep. gr.40.

–  Drain oil from bevel box using bolt -A-. –  Remove securing bolt for right flange shaft -arrow- with socket. To do this, screw 2 bolts into flange and counterhold flange with lever. –  Then screw in new bolt -A- and tighten. M6 bolt = 15 Nm M8 bolt = 60 Nm

–  Bolt puller -T10037- to right flange shaft.   Note To remove right flange shaft, use puller -T10037- to avoid damage to bearing of flange shaft. –  If necessary, lay a spacer (e.g. press piece -VW 434-) between bevel box carrier and knurled nut -T10371/1-. –  Use spindle-A- to align puller parallel to flange. –  Pull out right flange shaft.

–  Seal bevel box with cap. –  Remove particulate filter from engine and detach particulate filter support. → Rep. gr.26 –  Secure it to front wall of plenum chamber. –  Remove turbocharger support. → Rep. gr.21 –  Unbolt exhaust gas recirculation cooler but do not remove coolant hoses → Rep. gr.26.

–  Remove bevel box carrier bolts from engine and bevel box -arrows 1-, -arrows 2- and -arrow 3-. –  Remove bevel box carrier.

–  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, check whether heat shield -A- must be removed.