Volkswagen Workshop Service and Repair Manuals

Topping up gear oil in bevel box Conditions l  Bevel box must be in installation position. –  To top up oil, use Filling device for Haldex coupling 2 -VAS 6291-.

–  Route hose of filler device -VAS 6291- through engine compartment.

–  If present, remove shield for right drive shaft from bevel box -arrows-.   Note

Cover area beneath oil filler plug -B- with a cloth. –  Remove oil filler plug -B- from bevel box.

–  Disconnect adapter -A- from elbow -B-. –  Screw in adapter -A- to stop. –  A 5 mm hexagon key may be used to screw in adapter -VAS 6291/2-. –  Engage elbow -B- in adapter -A-. Alternatively, adapter -VAS 6291/3- can be used.

–  Screw in adapter -VAS 6291/3--A- to stop. –  Engage elbow -B- in adapter A-B-. l  Hose must not sag.

–  Ensure that valve -arrow- is closed. –  Screw oil reservoir -A- to filler device -VAS 6291-. –  Now open valve -arrow- and hold oil reservoir as shown in figure. Bevel box will now be filled. –  After a few minutes, raise vehicle.   Note t  If bevel box has been properly filled, oil will have run out at adapter -A-.

t  If no oil has run out, lower vehicle and perform filling procedure again. –  Raise vehicle. –  If oil has run out at adapter -A-, set oil reservoir aside (e.g. on a tool cart). Part of the excess oil will now run back into the oil reservoir. –  When no more oil flows back, remove filler device -VAS 6291-. –  Note that there is still oil in the hose of the filler device. –  Screw the old plug into the oil filler hole. –  Start engine, engage gear and allow gearbox to turn for approx. 2 minutes. –  Turn off engine and remove plug from oil filler hole. –  If necessary, again top up with gear oil to lower edge of filler hole. –  Screw in new plug -B-. –  Tighten plug for oil filler hole to specified torque → Chapter. If oil should get on bevel box, carefully remove it.

–  If present, attach shield for right drive shaft to bevel box -arrows- and tighten to specified torque → Chapter. –  Install noise insulation → General body repairs, exterior; Rep. Gr.50.