Installing bevel boxes as of model year 2010 — VW

Installing bevel boxes as of model year 2010
Install in reverse order of removal, observing the following:
Grease splines of differential with
grease for clutch plate splines
Electronic Parts Catalogue
.
Note
The aid of a second mechanic is required to position the bevel box.
Turn bevel box until propshaft flange is at top.
Lift bevel box and guide it past steering rack.
Turn bevel box into installation position and bolt fully onto manual gearbox. In the process, guide splines of bevel box lay shaft concentrically together with splines of differential.
Align splines of right stub shaft and differential bevel gear, turning stub shaft if necessary.
Note
In the process, ensure that installation position of stub shaft does not change (is not pushed out of bevel box).
Do not use securing bolts to pull bevel box onto gearbox, or bevel box will cant and bolt holes can break off.
Screw in lower bevel box/manual gearbox connecting bolts
arrows
and tighten them.
Screw in upper bevel box/manual gearbox connecting bolts
arrows
and tighten them.
Mount steering rack on universal joint and track rods on wheel bearing housing
Running gear, axles, steering
Rep. gr.
48
Removing and installing steering rack
.
Screw in countersunk bolt for right stub shaft with
socket and extended bit 6 mm
T10107 A
, and tighten it. Counterhold stub shaft using
counterhold tool
T10140
/
counterhold tool
T50053
while doing so.
Renew circlip
arrow A
and oil seal
arrow B
of stub shaft.
Grease splines of right stub shaft with
grease for clutch plate splines
Electronic Parts Catalogue
.
Bolt rear torque reaction support to cylinder block
Rep. gr.
10
Assembly mountings
.
Bolt bevel box carrier
3
to rear torque reaction support and bevel box (bolts
1
and
2
), note tightening sequence when doing so.
Push right drive shaft onto stub shaft
Running gear, axles, steering
Rep. gr.
40
Drive shafts
.
Install subframe with bracket for rear torque reaction support
Running gear, axles, steering
Rep. gr.
40
Removing and installing subframe
.
Install particulate filter
Rep. gr.
26
.
Install front propshaft
Rep. gr.
39
.
Check gear oil in gearbox
Chapter
.
Check gear oil in bevel box
Chapter
.
Install any noise insulation
General body repairs, exterior
Rep. gr.
50
Noise insulation
.
Gearbox carrier
3
to rear torque reaction support and bevel box
When installing bevel box carrier, observe following sequence:
Screw in bolts
2
hand-tight.
Tighten bolts
1
to 45 Nm.
Tighten bolts
2
to 45 Nm.
Specified torques
Chapter
“
Assembly overview - input shaft, output shafts, differential, bevel box and selector rods, all-wheel drive
”
Subframe; Assembly overview - subframe
Rep. gr.
40
Subframe
.
Exhaust system; Assembly overview - diesel particulate filter
Rep. gr.
26
Assembly overview - diesel particulate filter
.
Propshafts; Assembly overview - propshafts
Rep. gr.
39
Assembly overview - propshafts
.
Noise insulation; Assembly overview - noise insulation
Rep. gr.
50
Assembly overview - noise insulation
.