Removing and installing bevel box, Golf 2009 ► all-wheel drive — VW

VW
Golf
2004
Golf
2009
Scirocco
2009
Power transmission
6-speed manual gearbox 02Q Volkswagen R GmbH
Edition
12.2014
Removing and installing bevel box, Golf 2009 ► all-wheel drive
Special tools and workshop equipment required
Used oil collection and extraction unit
V.A.G 1782
Socket
T10107
Removing
To remove the bevel box, proceed as follows:
Remove noise insulation beneath engine and gearbox
General body repairs, exterior
Rep. gr.
50
Body - front; Noise insulation
.
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 heater
Rep. gr.
82
Removing and installing auxiliary heater Thermo Top V
.
Unbolt heat shield above right drive shaft
arrows
.
Remove right drive shaft
Running gear, axles, steering
Rep. gr.
40
Removing and installing drive shafts
.
Mark position of propshaft with flexible coupling relative to bevel box flange with paint.
Unbolt propshaft from bevel box
arrows
.
Push back front propshaft tube as far as stop.
Place a cloth on subframe to avoid damaging paint of propshaft when it is placed on subframe.
Place propshaft onto subframe.
Remove exhaust system bracket
arrows
from subframe.
Remove pendulum support from gearbox; bolts
1
and
2
.
Push engine/gearbox to front end, and support it using pendulum support, as shown in illustration.
A
= Collar bolt M10 x 35
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.
Disregard bolt
A
.
Unscrew bolt
1
and
2
securing gearbox carrier to engine and gearbox.
The illustration of the bolt head may differ from the original part.
Remove bevel box carrier.
Unscrew upper bolts
arrows
securing bevel box to gearbox.
Unscrew lower bolts
arrows
securing bevel box to gearbox.
Carefully press bevel box off gearbox and remove.
Installing
Install in reverse order of removal. During this step, observe the following:
Grease splines of differential for manual gearbox with grease
“G 000 100”
.
Push bevel box completely onto gearbox, ensuring that splines of bevel box input shaft and differential are centred when brought together.
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 towards gearbox, because otherwise the bevel box will cant and the securing eyes could break off.
Screw in upper bolts
arrows
securing bevel box to gearbox, and tighten them.
Screw in lower bolts
arrows
securing bevel box to gearbox, and tighten them.
Bolt bevel box carrier to engine and bevel box, observing tightening sequence of bolts
arrow 1
and
arrow 2
.
The illustration of the bolt head may differ from the original part.
Fill bevel box with axle oil
Chapter
Install right drive shaft
Running gear, axles, steering
Rep. gr.
40
Repairing drive shafts
.
If present, install heat shield for right drive shaft to bevel box
arrows
.
If removed, install coolant hoses
1
and
2
of auxiliary heater.
Do not open coolant system for this
Auxiliary heater
Rep. gr.
82
Removing and installing auxiliary heater Thermo Top V
.
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
.
Attach pendulum support to gearbox
Running gear, axles, steering
Rep. gr.
40
Assembly overview - Subframe, anti-roll bar, suspension links
.
Install noise insulation beneath engine and gearbox
General body repairs, exterior
Rep. gr.
50
Body - front; Noise insulation
.
Specified torques
Component
Nm
Upper bolts securing bevel box to gearbox
40 Nm + 90° turn further
1)
Lower bolts securing bevel box to gearbox
40 Nm + 90° turn further
1)
Heat shield for drive shaft to bevel box
25
Bevel box to gearbox
40 + 45° turn further
1)
1)
Renew.
Allocation of bolts for bevel box carrier to engine and bevel box
The illustration of the bolt heads may differ from the original part.
Component
Nm
Upper bolts
1
on gearbox
Screw in by hand, then tighten to 40 Nm
Upper bolt
2
on gearbox
40 Nm
Lower bolt
2
on gearbox
40 Nm
Lower bolt
1
on gearbox
Screw in by hand, then tighten to 40 Nm