Volkswagen Workshop Service and Repair Manuals

Installing bevel box Install in the reverse order of removal, observing the following: –  With gearbox installed, grease splines of differential with grease for clutch plate splines -G 000 100-.

–  If bevel box is to be renewed, install heat shield -A- as needed. –  Tighten bolts -arrows- to 5 Nm. –  Carefully pull the flange shaft out of the bevel box; (oil seal for flange shaft is not allowed to be damaged). –  Push bevel box completely onto gearbox, ensuring that splines of bevel box input shaft and differential are centred when brought together. –  If splines are correctly positioned and shafts are centred, then bevel box will slide to stop against gearbox.

A heat shield -arrow A- is installed on top of bevel box of some gearboxes. –  The upper bolts for securing bevel box to gearbox are accessible as follows: Bolt -arrow B- is accessible from beneath heat shield. Bolt -arrow C- is accessible from above heat shield.   Note Do not use securing bolts to pull bevel box onto gearbox, or bevel box will cant and bolt holes can break off.

–  Bolt bevel box carrier to engine and bevel box, observing tightening sequence of bolts -arrows 1-, -arrows 2- and -arrow 3- → Chapter. t  Shortly after start of production, the heads of bolts -arrows 2- were matched to the other bolts –  Install particle filter with support. → Rep. Gr.26 –  Screw on cooler for exhaust gas recirculation. (Do not open cooling system) → Rep. Gr.26 –  If present, install support for exhaust system → Rep. Gr.26. –  Install support for turbocharger → Rep. Gr.21 –  Insert the right flange shaft, turning the flange shaft if necessary. –  Bolt on flange shaft → Item. –  Attach right drive shaft to gearbox → Running gear, axles, steering; Rep. Gr.40.

–  If present, attach shield for right drive shaft to bevel box -arrows- and tighten to specified torque → Chapter. –  Install subframe and suspension links → Running gear, axles, steering; Rep. Gr.40.

–  Press engine/gearbox assembly towards bulkhead, carefully guiding bevel box pin into propshaft flange.   Note t  When removing and installing gearbox, do not damage seal in the propshaft flange -arrow-. Renew propshaft if damaged. t  Ensure that propshaft is horizontal when pushing onto guide pin.

–  Bolt propshaft with flexible coupling to bevel box flange -arrows- → Rep. Gr.39.   Note t  From gearbox manufacture date 28 05 7, there are threaded inserts (e.g. “HeliCoil”) in the bolting holes for the pendulum support.

t  Identification: shoulder along beginning of thread -arrow-. t  Ensure that the correct securing bolts and torque specifications are used. → Running gear, axles, steering; Rep. Gr.40

–  Attach pendulum support to gearbox, bolt -2- and bolt -3- → Running gear, axles, steering; Rep. Gr.40. –  Assemble exhaust system and attach exhaust system bracket to subframe → Rep. Gr.26. –  Check gear oil in bevel box → Chapter. –  Check gear oil in gearbox → Chapter. –  Install noise insulation → General body repairs, exterior; Rep. Gr.50.

–  Screw breather pipe -arrow-, if present, into bevel box and tighten to 10 Nm. If selector mechanism was removed from gearbox –  Assemble and adjust selector mechanism → Chapter. –  Install complete air filter housing → Rep. Gr.23. –  Check headlight adjustment of vehicles with -front vehicle level sender- → Electrical system; Rep. Gr.94.