Installing bevel box, 0AV — VW

🧭 Before you start

Grease the differential splines, push the bevel box squarely onto the gearbox until it seats, and only then fit the upper and lower securing bolts. Bolt on the bevel box carrier in the given sequence, refit the turbocharger support and drive in the right flange shaft while turning it. Fill the bevel box with axle oil, check the gearbox oil, then refit the right drive shaft, propshaft, pendulum support on new bolts, particulate filter, exhaust bracket and noise insulation.

Fits: VW Golf VII Variant (BA), VW Passat B7 saloon (362, 2010–2014), VW Passat B7 Variant (365, 2010–2014), VW CC (358, 2012–2017), VW Golf VII (5G, 2012–2020)

• Renewed: self-locking nuts

Don't miss

• Never use the securing bolts to draw the bevel box onto the gearbox; the casing cants and bolt holes break.
• Tighten the bevel box carrier bolts (A) and (B) in the specified sequence.
• Turn the right flange shaft as you drive it in to avoid damaging the bearings.
• Renew self-locking nuts and bolts, angle-tightened bolts, the pendulum support bolts and any cut cable ties.
• Some gearboxes have threaded inserts in the pendulum support holes; treat them with care.
• Fill the bevel box with axle oil and check the gearbox oil level before the undertray goes on.

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

📋 Procedure

1. If removed beforehand, install exhaust gas recirculation cooler 26Exhaust gas recirculation system; Removing and installing exhaust gas recirculation cooler. [Note: Refer to section "“Determining bevel box type”".Refer to section "“Removing bevel box”" for required special tools .Renew self-locking nuts and bolts after each removal.Renew bolts that are tightened with turning further angle after each removal.All cable ties which were opened or cut during removal must be renewed at the same points.]
2. Grease splines of manual gearbox differential with grease for clutch plate splines.
3. Push bevel box completely onto manual gearbox. When doing this, guide bevel box input shaft splines centrally together with differential.
4. If splines are correctly positioned and shafts are centred, then bevel box will slide to stop against gearbox. [Note: Do not use securing bolts to pull bevel box onto gearbox, or bevel box will cant and bolt holes can break off.]
5. Screw in upper securing bolts (arrows) for securing bevel box to gearbox and tighten them .

6. Screw in lower securing bolts (arrows) for securing bevel box to gearbox and tighten them .
7. Bolt on bevel box carrier. When doing this, observe tightening sequence of bolts (A) and (B).
8. Install turbocharger support (arrow)21Turbocharger; Assembly overview - turbocharger.
9. Drive in right flange shaft carefully, turning flange shaft as you do so, in order to avoid damaging bearings.
10. Secure flange shaft .
11. Fill bevel box with axle oil
12. Check gear oil in gearbox .
13. Install right drive shaft (C)Running gear, axles, steering40Drive shaft; Removing and installing drive shaft.
14. If removed, install coolant pipes (B) to engine and bevel box (arrow 2)82Auxiliary heaters.
15. Install heat shield (A) for drive shaft (arrows 1)Running gear, axles, steering40Drive shaft.
16. Bolt propshaft with flexible coupling to bevel box flange (arrows)39Propshaft; Removing and installing propshaft. [Note: On some gearboxes, there are threaded inserts, e.g. "“Heli coil”", in the bolting holes for the pendulum support .]
17. Install pendulum support using new bolts Running gear, axles, steering40.
18. Install particulate filter and attach exhaust system bracket to subframe 26Emission control.
19. Install noise insulation General body repairs, exterior66Noise insulation; Assembly overview - noise insulation.
20. Tighten bolts in stages as follows:

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