Removing and installing bevel box - vehicles with petrol engine — VW

🧭 Before you start

Loosen the right drive shaft bolt, raise the car level and remove noise insulation, right drive shaft, front exhaust and heat shield. Mark and unbolt the propshaft, push it into the tunnel, unbolt the pendulum support and move the engine forward with T10533. Remove the gearbox carrier, loosen the bevel box with the puller and VW 771 and take it off. Refit with a new retaining ring and O-ring, seat it by hand and plastic hammer, reassemble and check both oil levels.

Fits: VW Passat B8 (3G, 2014–)

• Renewed: propshaft

Don't miss

• Once the centre bolt is loosened, do not lower the vehicle back to the ground.
• Mark the propshaft flexible coupling against the bevel box output before unbolting.
• Fit a new retaining ring and O-ring on the right stub shaft.
• Seat the stub shaft with a plastic hammer; never draw the bevel box in with its bolts.
• Use new bevel box and pendulum support bolts.
• Check the bevel box gear oil and gearbox oil level after installation.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. Raise vehicle. All 4 supports of lifting platform must be at same height. [Note: After loosening centre bolt, do not lower vehicle to ground again.]
2. Depress brake pedal and loosen bolt of right drive shaft (arrow) (2nd mechanic needed)Running gear, axles, steering40Repairing drive shafts; Removing and installing drive shafts. [Note: So that the propshaft can be turned later in order to loosen it:]
3. Move selector lever to »N« position.
4. Remove noise insulation below engine and gearbox. General body repairs, exterior50Noise insulation.
5. Disconnect connector (1) from oil level and oil temperature sender G266.

6. Remove right drive shaft Running gear, axles, steering40Repairing drive shafts; Removing and installing drive shafts.
7. Remove drive shaft heat shield, if present, from bevel box Running gear, axles, steering40Repairing drive shafts; Removing and installing drive shafts.
8. ⚠ Risk of damage to decoupling element.Observe 26Emission control; Assembly overview – emission control. — Remove front exhaust system from engine, raise it and tie it in place 26Exhaust pipes/silencers; Assembly overview - silencer.
9. Unscrew bolts (A) and (B) from bevel box, and remove heat shield (1).
10. Mark position of propshaft with flexible coupling relative to output shaft of bevel box (arrows).
11. Unbolt propshaft from bevel box (arrows).
12. If necessary, counterhold at rear final drive when loosening or tightening propshaft. [Note: To loosen »next« bolt, turn propshaft further by turning rear wheels at same time.]
13. Unscrew pendulum support bolts (1) from gearbox.
14. Place a cloth on subframe to avoid damaging paint of propshaft when it is placed on subframe.
15. Push propshaft at front back to stop. Make sure not to damage seal (arrow) in centring bush.
16. Guide propshaft upwards into tunnel, and use a suitable piece of wood to support it on subframe.
17. Set up engine support T10533 as shown in figure and tighten bolts hand-tight.
18. Screw an M 8 x 30 mm bolt (1) with a washer (2) into threaded hole for noise insulation.
19. Move engine and gearbox as far forwards as possible by turning spindle of engine support T10533. Avoid collisions between components and radiator cowl.
20. Unbolt gearbox carrier.
21. Unscrew bolts (1) and (2), and remove carrier from bevel box.
22. Remove upper securing bolts (arrows) securing bevel box to gearbox.
23. Loosen lower securing bolts securing bevel box to gearbox and unscrew only as far as dimension (a).
24. Fit pullerT 10472 to bevel box.
25. Prepare multi-purpose toolVW 771 with a washer (a) and 2 sleeves from the supplementary set for engine and gearbox supportVW 540/1 B as shown in the illustration.
26. Bolt multi-purpose toolVW 771 onto puller T10472 and loosen bevel box from gearbox.
27. Remove multi-purpose toolVW 771 and puller T10472 from bevel box.
28. Unscrew lower securing bolts (arrows) and remove bevel box.
29. Grease splines of differential with grease for clutch plate splinesG 000 100.
30. Install new retaining ring (arrow A) and new O-ring (arrow B) on right stub shaft.
31. Insert bevel box and press against gearbox as far as it will go. [Note: Turn stub shaft if spline position is unfavourable (bevel box cannot be pressed to stop against gearbox).]
32. If splines are correctly positioned and shafts are centred, then bevel box will slide to stop against gearbox.
33. ⚠ To ensure that the retaining ring of the stub shaft engages properly in the differential bevel gear, strike the face of the spline stub with a plastic hammer. Do not pull bevel box forcefully against gearbox by turning securing bolts. Damage to gearbox or bevel box could result. — Screw on bevel box with new bolts (arrows) until finger-tight, then tighten. Torque setting: .
34. Install gearbox carrier. Observe installation location and tightening sequence of bolts .
35. If previously removed, attach drive shaft heat shield to bevel box Running gear, axles, steering40Repairing drive shafts; Removing and installing drive shafts.
36. Fit propshaft on bevel box. [Note: When removing and installing the bevel box, do not damage the seal in the propshaft flange (arrow). Renew propshaft if damaged.]
37. Join bevel box and propshaft by turning spindle of engine support T10533.
38. Remove engine support T10533.
39. Bolt propshaft onto bevel box (arrows)39Removing and installing propshaft.
40. If previously removed, install heat shield for propshaft.
41. Bolt on pendulum support using »new« bolts. Torque settings Running gear, axles, steering40.
42. Grease splines of stub shaft with greaseG 000 100.
43. Install right drive shaft Running gear, axles, steering40Repairing drive shafts; Removing and installing drive shaft.
44. Install parts of exhaust system 26Exhaust system.
45. Check gear oil in bevel box .
46. Following installation, check oil level in gearbox .
47. Install noise insulation General body repairs, exterior50Noise insulation.

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