Removing and installing bevel box, Golf 2004 ► and Passat 2006 ► with V6 engine — VW

VW
Golf
2004
Golf
2009
Golf Cabriolet
2012
Passat
2006
Passat Variant
2006
Scirocco
2009
Power transmission
6-speed dual clutch gearbox 02E Volkswagen R GmbH
Edition
07.2014
Removing and installing bevel box, Golf 2004 ► and Passat 2006 ► with V6 engine
Special tools and workshop equipment required
Used oil collection and extraction unit
V.A.G 1782
Socket
T10107
Removing
Raise vehicle. All 4 supports of lifting platform must be at same height.
Move selector lever to position
»P«
position.
Remove front right wheel.
Remove noise insulation.
Unbolt heat shield for right drive shaft from bevel box
arrows
.
Unbolt right drive shaft from gearbox flange.
Raise right drive shaft and secure with wire.
Unbolt bracket for exhaust system.
Remove retainer
2
for electrical cable to
oil level and oil temperature sender
G266
at subframe.
Remove bolts
1
and
2
from bevel box bracket.
First remove bolt
1
.
When installing, hand-tighten all bolts until the heads make contact. Then tighten bolts
2
.
Remove bracket
A
for bevel box.
Disconnect exhaust system.
Suspend exhaust system with a chain. To do this, insert
hook
3004
in openings on underbody (remove plugs if necessary).
Mark position of flexible coupling and bevel box flange relative to each other.
Unscrew flexible coupling of propshaft at bevel box.
Push propshaft horizontally as far back as possible.
Caution
Seal
arrow
in flange of propshaft must not be damaged when gearbox is removed. If seal is damaged, propshaft must be renewed.
When pendulum support/subframe bolts are loosened, the engine/gearbox assembly will swing slightly forwards.
Unscrew bolts
2
and
3
.
Push engine and gearbox forwards slightly and then pull propshaft off bevel box.
Place propshaft on top of bevel box and secure it in place to prevent it from falling down.
Remove subframe.
For information on how to remove the
subframe
, refer to
Rep. gr.
40
. Valuable information can be found there. If the job is done correctly, the subframe can be removed and reinstalled without subsequently causing increased tyre wear, which may lead to customer complaints. It is recommended to read this information
»before«
removing gearbox. Then the position of the
subframe
can be properly fixed and the subframe removed.
Position
used oil collection and extraction unit
V.A.G 1782
under gearbox.
Remove right flange shaft bolt
arrow 1
with
socket
T10107
.
Remove 4 securing bolts of bevel box on gearbox.
Pull off bevel box together with flange shaft from gearbox.
Installing
Install in reverse order of removal. During this step, observe the following:
Push bevel box together with flange shaft onto gearbox and turn flange shaft while doing so.
Bolt bevel box onto gearbox using 4 new bolts. Torque setting
Chapter
Screw in bolts
1
and
2
for securing bevel box bracket hand-tight.
Observe assembly order:
First tighten bolts
1
to 3 Nm.
Tighten bolts
2
to 35 Nm.
Finally tighten bolts
1
to 45 Nm.
Install subframe
Rep. gr.
40
.
Carefully press engine/gearbox assembly to plenum chamber bulkhead. Carefully guide bevel box pin into propshaft flange in the process.
Pay attention to oil seal.
Bolt pendulum support onto gearbox
2
and
3
with new bolts.
Install exhaust system without tension
Rep. gr.
26
.
Install right drive shaft
Rep. gr.
40
.
Check oil level in bevel box and top up
Chapter
.
Specified torques
Component
Nm
Heat shield for drive shaft to bevel box
25