Removing and installing bevel box (vehicles with a 5 or 6-cylinder engine) — VW

The following description deals with the Golf 1998 ä, Bora 1999 ä. Therefore differences must be considered, if necessary.

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

V.A.G 1669 Allen key extension 6 mm

V.A.G 1332 Torque wrench
Drip tray

Removing

Remove insulation tray below engine/gearbox, if fitted.

Mark position of propshaft flexible coupling to bevel box flange.
Disconnect propshaft with flexible coupling from bevel box flange (arrows).
Remove right drive shaft protective plate, if fitted.
Disconnect right-hand drive shaft from gearbox.
Tie-up drive shaft as high as possible. Do not damage paint on drive shaft.
Separate exhaust system at double clamp.

=> Repair group 26; Removing and installing parts of the exhaust system.
5/6-speed manual gearbox 02M FWD/gearbox
Removing and installing parts of the exhaust system.

Remove pendulum support from subframe (arrows -A-).
Press engine/gearbox forwards carefully.

Pull front propshaft carefully off centring pin.

Note:

When removing and installing the seal in the propshaft flange must not be damaged.

Unbolt (arrows) bevel box carrier from engine and bevel box.
Place container under gearbox and engine.

Remove oil drain plug -arrow A-.
Drain gearbox oil from bevel box.
Remove right drive shaft bolt -arrow- using V.A.G 1669 or 6 mm hexagon bit (commercial type).
Remove bevel box/gearbox securing bolts.
Press bevel box off gearbox.
Take out bevel box.

Installing

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

Notes:

Always renew O ring to seal bevel box/gearbox (arrow A) and O rings to seal sleeves for the oil supply system (arrow B and C), lightly coating them with oil.
Push bevel box completely onto gearbox, thereby ensuring that the bevel box input shaft splines are guided centrally onto the differential connecting piece.
Likewise engage splines of right flange shaft and bevel gear, turning flange shaft if necessary.
If the spline position and the central guide are correctly set then the bevel box will slide onto the stop against the gearbox.
Install bevel box carrier before screwing in bevel box/gearbox connecting bolts.

Do not pull the bevel box onto the gearbox using securing bolts otherwise the bevel box will cant and the securing eyes can break off.

When removing and installing do not damage seals in propshaft flanges.
Renew propshaft if damaged.
Ensure propshaft is horizontal when pushing onto guide pins.
Renew drive shaft seal, if fitted.

=> Running gear, Axles, Steering front and four-wheel drive; Repair group 40; Servicing drive shafts
Running gear, Axles, Steering front and four-wheel drive
Servicing drive shafts

Attach exhaust pipe to double clamp.

=> Repair group 26; Removing and installing parts of the exhaust system.
5/6-speed manual gearbox 02M FWD/gearbox
Removing and installing parts of the exhaust system.

Checking oil in gearbox with bevel box =>Page
34-64
.

Fit drive shafts to gearbox.

=> Running gear, axles, steering front and four-wheel drive; Repair group 40; Servicing drive shaft; Removing and installing drive shaft
Running gear, axles, steering front and four-wheel drive
Servicing drive shaft
Removing and installing drive shaft

Torque settings

Bevel box to manual gearbox / Always renew bolt · 40 Nm + 45°

Flexible coupling with heat shield to bevel box flange.

Installing bevel box/engine carrier stress-free

When installing gearbox support member observe the following sequence:

Screw in all bolts hand-tight.
Tighten bolts -B- (M10 x 22) first to 10 Nm.
Tighten bolts -A- (M10 x 50) to 50 Nm.
Tighten bolts -B- to 40 Nm.