Removing and installing bevel box (4-cylinder petrol engines) — VW

Removing and installing bevel box (4-cylinder petrol engines)
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Engine and gearbox jack
V.A.G 1383 A
with
universal support
V.A.G 1359/2
Socket
T10107 A
Counterhold tool
T10140
Counterhold tool
T50053
Grease
Electronic Parts Catalogue
Removing
Remove any noise insulation
General body repairs, exterior
Rep. gr.
50
Noise insulation
.
Loosen bolts
1
of propshaft heat shield
2
, and remove them.
Remove propshaft
Propshaft and rear final drive
Rep. gr.
39
.
Remove downstream catalytic converter
Exhaust system
Rep. gr.
26
Emission control
.
Note
The bracket may vary depending on vehicle equipment.
Remove bolts
1
and remove catalytic converter bracket
2
.
Unscrew bolts
1
and
2
and remote gearbox carrier
3
from rear torque reaction support and from bevel box.
Remove bolt
1
from support mounting
3
of engine mounting
2
.
Remove support
3
.
Unscrew bolts
2
and bolt
3
, and remove rear torque reaction support
1
from cylinder block
4
.
Remove wheel.
Unscrew right suspension link from swivel joint.
If fitted, unscrew nut from bottom of vehicle level sender
arrow
.
Using
ball joint puller
T40010
, pull suspension link from swivel joint.
Pull right drive shaft from stub shaft of bevel box
Running gear, axles, steering
Rep. gr.
40
Repairing drive shafts; Removing and installing drive shafts
and tie up.
Pull connector off
oil level and oil temperature sensor
G266
, and unclip wiring harness.
Unscrew bolts
4
.
Unscrew bolt
2
, and remove support.
Note
If bolt
2
has been loosened, tighten this bolt last as it also carries out a vertical tolerance compensation.
Using
tensioning strap
T10038
, pull engine and gearbox towards front, and secure them in this position.
Remove circlip
arrow A
from right stub shaft.
Remove countersunk bolt for right stub shaft with
socket and extended bit 6 mm
T10107 A
. Counterhold stub shaft with
counterhold tool
T10140
/
counterhold tool
T50053
when doing this.
Remove top bevel box/dual clutch gearbox connecting bolts
arrows
.
Remove bottom bevel box/dual clutch gearbox connecting bolts
arrows
.
Note
A second mechanic is required for further removal.
Position
used oil collection and extraction unit
VAS 6622A
under gearbox.
WARNING
Danger of injury from hot gear oil.
Wear eye protection.
Wear acid-resistant gloves.
Carefully push bevel box off dual clutch gearbox.
Turn bevel box until propshaft flange is at top.
Remove bevel box out between sump and subframe.
Place bevel box on
engine and gearbox jack
V.A.G 1383 A
or
engine and gearbox jack
VAS 6931
.
Installing
Install in reverse order of removal. During this step, observe the following:
Lubricate right stub shaft splines
arrow
with
all-purpose grease
G 060 735 A2
.
Note
The aid of a second mechanic is required to position the bevel box.
Turn bevel box until propshaft flange is at top.
Guide bevel box in between sump and subframe.
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
When installing, 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 bottom bevel box/dual clutch gearbox connecting bolts
arrows
and tighten bolts first hand-tight, then tighten to specified torque
Chapter
.
Screw in top bevel box/dual clutch gearbox connecting bolts
arrows
and tighten bolts first hand-tight, then tighten to specified torque
Gearbox mechanical operating mechanism assembly, differential lock
Rep. gr.
34
Assembly overview - bevel box
.
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 retaining ring
arrow A
and oil seal
arrow B
of stub shaft.
Lubricate right stub shaft splines with
all-purpose grease
G 060 735 A2
.
Screw rear torque reaction support to cylinder block, tighten bolts first hand-tight, then tighten to specified torque
Engine, Assembly, Cylinder, Crankcase
Rep. gr.
10
Assembly mountings
.
Install support.
Bolt gearbox carrier
3
onto rear torque reaction support and bevel box (bolts
1
and
2
), note tightening sequence and specified torque when doing so
Chapter
.
Tighten bolts first hand-tight, then tighten to specified torque.
Press right drive shaft onto gearbox stub shaft
Running gear, axles, steering
Rep. gr.
40
Repairing drive shafts; Removing and installing drive shaft
.
Install support at front. Tighten bolts first hand-tight, then tighten them to specified torque.
Connect connector to
oil level and oil temperature sensor
G266
, and route wiring harness.
Bolt suspension link to swivel joint
Front suspension, drive shaft
Rep. gr.
40
Assembly overview - subframe, anti-roll bar, suspension links
.
If fitted, screw on nut at bottom of vehicle level sender.
Fit wheel
Maintenance
Booklet
19.1
.
Fit catalytic converter bracket
2
using bolts
1
, then tighten to specified torque.
Install propshaft
Propshaft and rear final drive
Rep. gr.
39
.
Insert heat shield
2
, screw in bolts
1
, and then tighten bolts to specified torque.
Install downstream catalytic converter
Exhaust system
Rep. gr.
26
Exhaust gas cleaning
.
Top up DSG transmission oil
Chapter
.
Secure opened/removed cable ties to original position.
Install any noise insulation
General body repairs, exterior
Rep. gr.
50
Noise insulation
.