Removing and installing bevel box (vehicles with 4-cylinder engine) — VW

Special tools, testers and auxiliary items

Engine support bracket 10-222A with supports10-222A/1
Engine press tool 3300 A
Socket 6 mm AF V.A.G 1669
Drip tray

Removing

For vehicles with coded radio obtain radio code.

With the ignition switched off disconnect the battery earth strap.
Remove air hose between air cleaner and air intake elbow.
Remove right-hand engine console/sub-frame securing bolt (arrow), first remove cable connector retaining plate -A- if fitted.

Fit support bar 10-222 A together with legs 10-222 A/1 and support engine/gearbox.

Disconnect engine carrier at front console.
Remove coolant expansion tank and lay to one side.

Note:

Do not open cooling system.

Remove hexagon bolt -A- from left hand assembly mounting -B-.

Remove bevel box/engine support.

Remove balance weight -A- from sub-frame.
Mark position of propshaft flexible coupling to bevel box flange.

Disconnect propshaft with flexible coupling from bevel box flange (arrows).
Push propshaft back onto stop.
Remove heat shield from vehicle floor.
Separate exhaust system in front of catalyst.

=> Repair group 26; Removing and installing parts of exhaust system.
5-Speed manual gearbox 02C four wheel drive
Removing and installing parts of exhaust system.

Disconnect right-hand drive shaft from gearbox.
Lift engine/gearbox slightly using support bar 10-222A spindles.

Fit press tool 3300 A.
Press engine/gearbox forwards.

Remove air guide -A- from right hand wishbone.
Drive clips out through holes in wishbone (arrows).

Move drive shaft forwards.

Remove bevel box carrier from engine and bevel box (arrows).
Place container under the gearbox.
Using a screwdriver lever cover plate out of drive flange.
Remove right hand drive shaft bolt using V.A.G 1669 or 6 mm socket (commercial type).
Remove drive shaft with drive flange.
Remove bevel box/gearbox securing bolts.
Press bevel box off gearbox.

Note:

When removing and installing the gearbox do not damage the seal in the propshaft flange.

Take out bevel box.

Installing

Installation is carried out in the reverse sequence, when doing this note the following:

Always renew sealing rings.
Press bevel box completely into the manual gearbox. To do this rotate drive shaft flange slowly.

If the gear teeth are correctly positioned and guided centrally then the bevel gearbox will slide fully onto the manual gearbox.

Note:

Do not pull the bevel box onto the gearbox using the securing bolts, because the bevel box will be canted and the securing eyes may break off.

Installing bevel box/engine carrier stress-free => Page
34-62
.
Checking oil level => Page
34-71
.
Specification => Page
00-3
.

Tightening torques

Bevel box to gearbox · 40 Nm
Left console left to gearbox · 25 Nm
Right engine console to sub-frame · 25 Nm
Front console to engine carrier · 50 Nm
Left console to sub-frame · 50 Nm
Balance weight to sub-frame · 30 Nm
Bevel box support to engine · 40 Nm
/ Bevel box support to bevel box · / 40 Nm
Propshaft to bevel box · => Page 39-86
Drive shaft to drive flange · 45 Nm

Bevel box/engine carrier => Page
34-62
.

Installing bevel box/engine carrier stress-free

Prerequisites:

Gearbox and bevel box installed and secured to engine.

When installing gearbox support member observe the following sequence:

Screw in all bolts hand-tight.
Tighten bolts -B- and -C- first to 8 Nm.
Tighten bolts -A- to 25 Nm.
Tighten bolts -B- and -C- to 40 Nm.