Dismantling and assembling bevel box: Audi A3

🧭 Before you start

Fits: Audi A3 (8L, 1996–2003)

• Opens: gearbox oil
• Special tools named: puller
• Renewed: drive flange cap

Don't miss

• If the output flange hexagon nut is not to be loosened, then the bevel box can be held in gearbox support2004 for dismantling and assembling.
• The pinion housing can also be removed and installed with the output flange fitted.
• If the oil seal has to be renewed then it must be levered out now.
• Inner race can also be pulled off using tapered roller bearing pullerV.A.G 1582 and adapterV.A.G 1582/3 but first place thrust plate40-105 on input shaft.
• Table of adjustments .

📋 Procedure

1. Place used oil collection and extraction unitV.A.G 1782 below gearbox.
2. Drain gear oil.
3. Secure bevel box in gearbox support. [Note: If the output flange hexagon nut is not to be loosened, then the bevel box can be held in gearbox support2004 for dismantling and assembling.]
4. Remove hexagon nut for output flange.
5. Remove output flange.

6. Pry out oil seal using screwdriver.
7. Remove small tapered roller bearing inner race for shaft bevel gear.
8. Remove pinion housing (1); to do so, screw hexagon bolts (arrows) in evenly so that pinion housing does not cant. [Note: The pinion housing can also be removed and installed with the output flange fitted.]
9. Remove shim "“S3”".
10. Press small tapered roller bearing outer race out of pinion housing.
11. Pull large tapered roller bearing outer race out of pinion housing.
12. Remove shaft bevel gear with shim "“S4”" and spacer ring.
13. Pull off large tapered roller bearing inner race from shaft bevel gear; to do so, fit adapter and apply tension behind the bearing rollers.
14. Then turn bearing and retighten adapter.
15. Bolt puller T10037 to flange shaft (right-side)/drive flange (right-side).
16. Use knurled nut T10037/1 and lower support (A) to align puller parallel with flange shaft/drive flange.
17. Pull out flange shaft/drive flange.
18. If the oil seal has to be renewed then it must be levered out now.
19. Press off drive flange from output shaft.
20. Remove cover, when doing this screw hexagon bolts (A) in evenly so that the cover does not cant.
21. Press large tapered roller bearing outer race out of cover.
22. Remove bevel gear with input shaft.
23. Press off large tapered roller bearing inner race from bevel gear.
24. Press off small tapered roller bearing inner race from input shaft. [Note: Inner race can also be pulled off using tapered roller bearing pullerV.A.G 1582 and adapterV.A.G 1582/3 but first place thrust plate40-105 on input shaft.]
25. Press small tapered roller bearing outer race out of final drive housing.
26. Remove circlip for roller bearing from final drive housing: lever one end of circlip out of groove by turning screwdriver (A) .
27. Lift this end of circlip using screwdriver (B) and lever out circlip further by re-applying screwdriver.
28. Pull roller sleeve out of final drive housing. [Note: Table of adjustments .]
29. Carefully press roller bearing into final drive housing as far as stop.
30. Fit new circlip in final drive housing.
31. Fit shim "“S2”" and press small tapered roller bearing outer race into final drive housing. [Note: Interrupt pressing operation as soon as possible to allow the tubeVW 771/33 to be seated over the complete circumference of the outer race.]
32. Press small tapered roller bearing inner race onto input shaft.
33. Press large tapered roller bearing inner race onto bevel gear.
34. Insert bevel gear with input shaft into final drive housing.
35. Fit shim "“S1”" into cover and press in large tapered roller bearing outer race.
36. Install cover with new O-ring. [Note: Keep straight when installing, tighten securing bolts diagonally and in stages]
37. Press large tapered roller bearing inner race onto shaft bevel gear.
38. Insert shaft bevel gear with shim "“S4”" and spacer ring into final drive housing.
39. Press small tapered roller bearing outer race into pinion housing.
40. Press large tapered roller bearing outer race into pinion housing.
41. Fit shim "“S3”" onto final drive housing.
42. Install pinion housing with new O-ring. [Note: Keep straight when installing, screw in and tighten securing bolts diagonally and in stagesThe pinion housing can also be removed and installed with the output flange fitted.]
43. Insert small tapered roller bearing inner race for shaft bevel gear.
44. Drive in new oil seal for output flange until flush.
45. Pack space between sealing lip and dust lip half-full with sealing greaseG 052 128 A1.
46. Install output flange.
47. Tighten hexagon nut for output flange.
48. Drive in new oil seal for flange shaft/drive flange with output shaft as far as stop .
49. Pack space between sealing lip and dust lip half-full with sealing greaseG 052 128 A1.
50. Press drive flange onto output shaft.
51. Carefully drive in flange shaft/drive flange with output shaft (while turning).
52. Secure flange shaft/drive flange with output shaft .
53. Renew drive flange cap, if fitted.

Other AUDI procedures

• Removing and installing toothed belt – Audi · 56 torque figures
• Removing engine – Audi A8 D3 · 41 torque figures
• Removing camshaft timing chain from camshafts – Audi A6/A7 C7 · 38 torque figures
• Installing engine – Audi A8 D4 · 36 torque figures
• Removing and installing camshaft timing chain · 29 torque figures
• Removing and installing wire for side airbag (front) – Audi Q7
• Removing and installing seat ("Low") - outer seats in 2nd row
• Removing and installing head restraint - 3rd row – Audi Q7
• Removing and installing seat pan cover and padding - seat without seat depth adjustment
• Removing and installing backrest cover and padding - outer seat in 2nd row