Volkswagen Workshop Service and Repair Manuals

Dismantling bevel box

• ‒ Drain gearbox oil.
• ‒ → Secure bevel box in gearbox support.

• A - Nut M12 x 10

Note:

If the output flange hexagon nut is not to be loosened, then the bevel box can be held in gearbox support 2004 for dismantling and assembling.

• ‒ → Remove output flange hexagon nut.

• A - Socket for 3/4" drive
• B - Nut M12 x 10

• ‒ Take off output flange.
• ‒ Lever out seal using a screwdriver.

• ‒ Take out shaft bevel gear small taper roller bearing inner race.
• ‒ → Remove pinion housing.

• Bolt hexagon bolts -A- in evenly so that the pinion housing is not canted.

Note:

Pinion housing can also be removed and installed with the output flange fitted.

• ‒ Take off shim S3.

• ‒ → Press small taper roller bearing outer race out of pinion housing.

B - Internal puller 46...58 mm, e.g. Kukko 21/7

• ‒ → Pulling large taper roller bearing outer race out of pinion housing.

A - Internal puller 46 ... 58 mm, e.g. Kukko 21/7

B - Counter support, e.g. Kukko 22/2

• ‒ Take output bevel gear out with shim S4.

Gearbox for vehicles with 6 cylinder injection engine:

• ‒ Take off spacer ring.

• ‒ → Pulling large taper roller bearing inner race off shaft bevel gear.

• Fit extractor and tension well behind the bearing rollers. Then turn bearing and retension extractor.

• ‒ → Remove cover.

• Bolt hexagon bolts -A- in evenly so that the cover does not cant.

Note:

Lever out seal first if necessary.

• ‒ → Pressing large taper roller bearing outer race out of cover.

A - Internal puller 56...70 mm, e.g. Kukko 21/8

• ‒ Remove bevel gear with input shaft.
• ‒ → Pulling large taper roller bearing inner race off bevel gear.

• Fit extractor and tension well behind the bearing rollers. Then turn bearing and retension extractor.

Note:

The large inner race can also be pressed off using separating device 22...115 mm, e.g. Kukko 17/2 and press tool VW 407.

• ‒ → Pressing small taper roller bearing inner race off input shaft

A - Separating device 22 ... 115 mm, e.g. Kukko 17/2

Note:

Inner race can also be pressed off using taper roller bearing puller V.A.G 1582 and extractor V.A.G 1582/3 but first place press piece 40-105 on input shaft.

• ‒ → Pressing small taper roller bearing outer race out of final drive housing.

A - Internal extractor 45 ... 58 mm, e.g. Kukko 21/7

• ‒ Remove circlip for roller bearing from final drive housing.
• ‒ → Pulling roller bearing out of final drive housing.

A - Counter support, e.g. Kukko 22/1

B - Internal puller 22 ... 28 mm, e.g. Kukko 21/4

• ‒ → Pulling sleeves for oil supply out.

A - Internal extractor 8 ... 12 mm, e.g. Kukko 21/02

B - Counter support, e.g. Kukko 22/1

• Pulling out is also possible when bevel box is not dismantled.

Assembling bevel box

Note:

See adjustment overview .

• ‒ → Pressing sleeves for oil supply in.

• Installation position: Side with inscription towards press tool.
• Carefully press in onto stop.
• The sleeves can be pressed in when the bevel box is not dismantled using press tool VW 409.

• ‒ → Pressing roller bearing in final drive housing.

• The inscription points towards press tool.
• Carefully press in onto stop.

• ‒ Fit new circlip in final drive housing.

• ‒ → Pressing small taper roller bearing outer race into final drive housing.

• First fit shim S2.

Note:

Interrupt pressing operation as soon as possible to allow the press tool VW 711/33 to be seated over the complete circumference of the outer race.

• ‒ → Pressing small taper roller bearing inner race onto input shaft.

• ‒ → Pressing large taper roller bearing inner race onto bevel gear.
• ‒ Insert bevel gear with input shaft into final drive housing.

• ‒ → Pressing large taper roller bearing outer race into cover.

• Fit shim S1 before pressing in.

• ‒ Install cover with new O-ring.

Note:

Do not cant during installation, tighten securing bolts in a diagonal sequence and in stages.

• ‒ → Pressing large taper roller bearing inner race onto shaft bevel gear.
• ‒ Insert shaft bevel gear with shim S4 into final drive housing.

Gearbox for vehicles with 6 cylinder injection engine:

• ‒ Before fitting shim S4 fit spacer ring with chamfer pointing towards shaft bevel gear.

• ‒ → Pressing small taper roller bearing outer race into pinion housing.

• ‒ → Pressing large taper roller bearing outer race into pinion housing.

• ‒ → Fit shim S3 to final drive housing.
• ‒ Install pinion housing with new O-ring.

Notes:

• ◆ The arrow -A- cast in the housing is opposite the oil drain plug -B-.
• ◆ Do not cant when installing, tighten securing screws in a diagonal sequence and in stages.
• ◆ Pinion housing can be removed and installed with output flange fitted.

• ‒ Fit small taper roller bearing inner race for shaft bevel gear.
• ‒ → Drive new oil seal for output flange in flush.

• ‒ Install output shaft.

Note:

→ Identifying output flange:

I - Gearbox for vehicles with 6-Cyl. injection engine: Splines recessed (arrow).

II - Gearbox for vehicles with 4-Cyl. engine:

Splines over full length.

• ‒ → Fit and tighten output flange hexagon nut to torque setting.

• A - Socket for 3/4" drive
• B - Nut M12 x 10
• Nut and shaft bevel gear threads must be clean.

• ‒ Drive new seal for drive flange/output shaft onto stop => Page 39-4 .
• ‒ → Pressing drive flange off output shaft.

• ‒ → Pressing drive flange onto output shaft.