Removing and installing bevel box - vehicles with 6-cylinder engine — AUDI

🧭 Before you start

Remove noise insulation, split the exhaust, unbolt the propshaft and pendulum support, wedge the engine forwards, free the right driveshaft and drain the gear oil. Remove the flange shaft bolt, the bracket bolts, the bottom and then (with the air cleaner out) top bevel box bolts, and lower it out. Install with new seals and bolts, tighten the bracket bolts in sequence, refit driveshaft, propshaft and exhaust, and fill the gear oil.

Fits: Audi TT Mk1 (8N)

• Renewed: o-ring between bevel box, bolts

Don't miss

• Always renew the O-ring and the oil-drilling seals between bevel box and gearbox, lightly lubricated.
• Fit the bracket bolts hand-tight, then bolts (1) to 3 Nm, bolts (2) to 35 Nm, bolts (1) to 45 Nm.
• Do not draw the bevel box on with its bolts; guide the input splines centrally first.
• A damaged propshaft flange seal means a new propshaft; slide it onto the guide pin without tilting.
• Use new bolts on the bevel box and pendulum support.

Written for this job from the workshop steps below · TorqFix editorial.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Remove centre noise insulation (fasteners 1 ... 3).
2. Release fasteners in wheel housing (left and right).
3. Remove bolts (arrows 1 ... 3). [Note: (Arrows A and B) can be disregarded.]
4. Remove noise insulation (right-side) (arrows).
5. Disconnect exhaust system at clamp (arrows).

6. Push clamp towards the rear.
7. Mark position of flexible coupling on bevel box flange.
8. Unscrew propshaft with flexible coupling from bevel box flange (arrows). [Note: When slackening off bolts, counterhold propshaft flange/final drive with a suitable lever.]
9. Press front propshaft tube as far as possible towards the rear. [Note: After loosening bolts (A) (⇒ following illustration N34-887) the engine/gearbox assembly will swing slightly to the front.]
10. ⚠ Make sure that the seal (arrow) in the flange of the propshaft is not damaged when removing and installing. If seals are damaged, the propshaft must be renewed. — Unbolt pendulum support at subframe (arrows A).
11. Press engine/gearbox to front and place a block of wood between anti-roll bar and gearbox housing (arrow) as shown in illustration.
12. Turn steering wheel to the left.
13. Unscrew heat shield for drive shaft on right of bevel box (arrows).
14. Unbolt drive shaft (right side) from gearbox flange shaft.
15. Lift drive shaft (right-side) up and secure with wire.
16. Place used oil collection and extraction unitV.A.G 1782 below gearbox.
17. Remove drain plug (arrow 2) and allow gear oil to drain off.
18. Unscrew bolt for flange shaft (right-side) (arrow 1) using hexagon keyV.A.G 1669.
19. Unscrew bolts (1) and (2) at bracket (A) for bevel box.
20. Remove two bottom bolts securing bevel box to gearbox.
21. Remove cover panel (front left) (arrows).
22. Detach air intake hose (2) at throttle valve module J338.
23. Unplug electrical connector for air mass meter G70(3).
24. Remove bolts (1) and (4).
25. Move electrical wire (arrow) clear.
26. Take out air cleaner housing.
27. Remove two top bolts securing bevel box to gearbox.
28. Detach bevel box from gearbox.
29. Take out bevel box downwards.
30. Always renew O-ring between bevel box and gearbox (arrow A) and seals on oil supply drillings (arrow B, C).
31. Lightly lubricate O-ring and seals prior to installing.
32. Push bevel box completely onto gearbox, at the same time ensuring that the splines on the bevel box input shaft are guided centrally onto the differential connecting piece. [Note: Do not use the securing bolts to pull the bevel box onto the gearbox. This could cause the bevel box to tilt and the securing eyes may break off.]
33. Tighten securing bolts between bevel box and gearbox. Use new bolts.
34. Screw in bolts (1) and (2) for bevel box bracket only hand-tight at this stage.
35. Observe the further tightening sequence:
36. First tighten bolts (1) to 3 Nm. — 3 Nm (2.2 lb-ft)
37. Tighten bolts (2) to 35 Nm. — 35 Nm (26 lb-ft)
38. Tighten bolts (1) to 45 Nm. — 45 Nm (33 lb-ft)
39. Tighten bolt for flange shaft (right-side) (arrow) using hexagon keyV.A.G 1669.
40. Bolt drive shaft (right-side) to gearbox flange shaft Running gear, front-wheel drive and four-wheel drive40.
41. Install heat shield for drive shaft (right-side) (arrows).
42. Remove block of wood between gearbox housing and anti-roll bar.
43. Press engine/gearbox assembly towards bulkhead; the bevel box pin must be guided carefully into the propshaft flange when doing this.
44. Slide propshaft onto guide pin without tilting.
45. ⚠ The seal (arrow) in the propshaft flange must not be damaged when removing and installing. If seals are damaged, the propshaft must be renewed. — Secure pendulum support to subframe (arrows A).
46. Use new bolts.
47. Bolt propshaft with flexible coupling onto bevel box flange (arrows)5/6-speed manual gearbox 02M, four-wheel drive / final drive39.
48. Install exhaust system free of stress 26.
49. Fill up gear oil in manual gearbox with bevel box .

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