Removing and installing bevel box, vehicles with diesel engine — VW

Removing and installing bevel box, vehicles with diesel engine
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Engine and gearbox jack
V.A.G 1383 A
or
engine and gearbox jack
VAS 6931
Socket
T10061
Used oil collection and extraction unit
VAS 6622A
Grease for clutch plate splines
Electronic Parts Catalogue
Removing
If fitted, remove noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation
.
Remove propshaft
Rep. gr.
39
Propshaft; Removing and installing propshaft
.
Remove catalytic converter
Rep. gr.
26
Cleansing exhaust emissions; Removing and installing catalytic converter
.
Remove particulate filter
Rep. gr.
26
.
Remove bolts
1
and remove catalytic converter bracket
2
.
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.
If fitted, unscrew nut from bottom of vehicle level sender
arrow
.
Remove bolts
1
and
2
. Remove gearbox carrier
3
from rear torque reaction support and from bevel box.
Remove bolts
2
and bolt
3
. Remove torque reaction support
1
backwards from cylinder block
4
.
Unscrew threaded connections
arrow
of anti-roll bar/subframe
2
using
socket and multi-point bit
T10061
.
Swing anti-roll bar
1
away from subframe.
Remove bolt
1
from support mounting
3
of engine mounting
2
.
Remove support
3
.
Remove top bevel box/dual clutch gearbox connecting bolts
arrows
.
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.
Remove bottom bevel box/dual clutch gearbox connecting bolts
arrows
.
Note
A second mechanic is required for further removal.
Carefully push bevel box off dual clutch gearbox.
Turn bevel box until propshaft flange is at top.
Lower bevel box, and guide it past subframe by turning it several times.
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. Observe the following:
Lubricate stub shaft splines of differential with
all-purpose grease
.
Lubricate right stub shaft splines
arrow
with
all-purpose grease
.
Note
The aid of a second mechanic is required to position the bevel box.
Turn bevel box until propshaft flange is at top.
Lift bevel box and guide it past steering rack.
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 securing eyes can break off.
Screw in bottom bevel box/dual clutch gearbox connecting bolts
arrows
and tighten to specified torque
Chapter
.
Screw in top bevel box/dual clutch gearbox connecting bolts
arrows
and tighten to specified torque
Chapter
.
Swing anti-roll bar
1
onto subframe.
Tighten threaded connections
arrow
on anti-roll bar/subframe
2
using
socket and multi-point bit
T10061
.
Renew retaining ring
arrow A
and oil seal
arrow B
of stub shaft.
Lubricate right stub shaft splines with
all-purpose grease
.
Fit rear torque reaction support
1
on cylinder block
4
. Tighten bolts
2
and bolt
3
.
Bolt gearbox carrier
3
onto rear torque reaction support and bevel box (bolts
1
and
2
), note tightening sequence when doing so
Fig.
.
Press right drive shaft onto gearbox stub shaft
Running gear, axles, steering
Rep. gr.
40
Repairing drive shafts; Removing and installing drive shaft
.
Install subframe with bracket for rear torque reaction support
Running gear, axles, steering
Rep. gr.
40
Repairing front suspension; Removing and installing subframe
.
Install diesel particulate filter
Rep. gr.
26
Emission control; Removing and installing diesel particulate filter
.
Install front propshaft
Rep. gr.
39
.
Check gear oil in bevel box
Chapter
.
If present, install noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation
.
Specified torque
Chapter
“
Assembly overview - bevel box
”
Rep. gr.
26
Emission control; Assembly overview - emission control
Rep. gr.
10
Assembly mountings; Assembly overview - assembly mountings