6-speed manual gearbox 02Q Volkswagen R GmbH — Removing and installing bevel box, Golf 2009 ► all-wheel drive — VW

🧭 Before you start

Fits: VW Golf VI (5K, 2008–2013)

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• Mark position of propshaft with flexible coupling relative to bevel box flange with paint.
• Unscrew bolt for right flange shaft (arrow) using socket. To do this, screw 2 bolts into flange and counterhold flange shaft with an assembly lever.
• Do not use securing bolts to pull bevel box towards gearbox, because otherwise the bevel box will cant and the securing eyes could break off.
• Note that there are threaded inserts (e.g. HeliCoil) in the holes for the pendulum support.Identification: shoulder along beginning of thread (arrow).

🔧 Engine codes this applies to

📋 Procedure

1. Remove noise insulation beneath engine and gearbox General body repairs, exterior50Body - front; Noise insulation.
2. To gain more clearance in vehicles with auxiliary heaters, remove coolant hoses (1) and (2) for auxiliary heater from engine and from body. Do not open coolant circuit Auxiliary heater82Removing and installing auxiliary heater Thermo Top V.
3. Unbolt heat shield above right drive shaft (arrows).
4. Remove right drive shaft Running gear, axles, steering40Removing and installing drive shafts.
5. Mark position of propshaft with flexible coupling relative to bevel box flange with paint.

6. Unbolt propshaft from bevel box (arrows).
7. Push back front propshaft tube as far as stop.
8. Place a cloth on subframe to avoid damaging paint of propshaft when it is placed on subframe.
9. Place propshaft onto subframe.
10. Remove exhaust system bracket (arrows) from subframe.
11. Remove pendulum support from gearbox; bolts (1) and (2).
12. Push engine/gearbox to front end, and support it using pendulum support, as shown in illustration.
13. Unscrew bolt for right flange shaft (arrow) using socket. To do this, screw 2 bolts into flange and counterhold flange shaft with an assembly lever.
14. Unscrew bolt (1) and (2) securing gearbox carrier to engine and gearbox.
15. Remove bevel box carrier.
16. Unscrew upper bolts (arrows) securing bevel box to gearbox.
17. Unscrew lower bolts (arrows) securing bevel box to gearbox.
18. Carefully press bevel box off gearbox and remove.
19. Grease splines of differential for manual gearbox with grease "“G 000 100”".
20. Push bevel box completely onto gearbox, ensuring that splines of bevel box input shaft and differential are centred when brought together. [Note: Do not use securing bolts to pull bevel box towards gearbox, because otherwise the bevel box will cant and the securing eyes could break off.]
21. Screw in upper bolts (arrows) securing bevel box to gearbox, and tighten them.
22. Screw in lower bolts (arrows) securing bevel box to gearbox, and tighten them.
23. Bolt bevel box carrier to engine and bevel box, observing tightening sequence of bolts (arrow 1) and (arrow 2).
24. Fill bevel box with axle oil
25. Install right drive shaft Running gear, axles, steering40Repairing drive shafts.
26. If present, install heat shield for right drive shaft to bevel box (arrows).
27. If removed, install coolant hoses (1) and (2) of auxiliary heater.
28. Bolt propshaft with flexible coupling to bevel box flange (arrows). [Note: Note that there are threaded inserts (e.g. HeliCoil) in the holes for the pendulum support.Identification: shoulder along beginning of thread (arrow).]
29. Attach pendulum support to gearbox Running gear, axles, steering40Assembly overview - Subframe, anti-roll bar, suspension links.
30. Install noise insulation beneath engine and gearbox General body repairs, exterior50Body - front; Noise insulation.

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