Removing bevel box, vehicles with turbo diesel engine: VW Golf V / Jetta

🧭 Before you start

Fits: VW Golf V / Jetta (1K, 2003–2009)

Don't miss

• Mark position of propshaft with flexible coupling relative to bevel box flange.
• After pendulum support securing bolts are loosened, the engine/gearbox assembly will swing slightly forwards (towards front of car). Ensure that seal (arrow) in flange of propshaft is not damaged during removal or installation.
• Unbolt exhaust gas recirculation cooler but do not remove coolant hoses 26Assembly overview - exhaust gas recirculation cooler
• If bevel box is to be renewed, check whether heat shield (A) must be removed.

📋 Procedure

1. To do this, it may be necessary to remove complete air filter housing 23Repairing diesel direct injection system; Dismantling and assembling air filter.
2. Remove securing clip (2) for gear selector cable (1) from gearbox selector lever (3) and pull gear selector cable (1) off pin (arrow).
3. Pull locking mechanism forward to stop in (direction of arrow 1) and then lock by turning to left in (direction of arrow 2).
4. Then push relay lever forwards ((in direction of arrow 3)).
5. Remove cable support bracket from gearbox (arrows), lay to side and secure with wire.

6. Remove breather pipe (arrow) from bevel box.
7. Raise vehicle.
8. Remove noise insulation General body repairs, exterior50Noise insulation.
9. Separate exhaust system at clamp and remove exhaust system bracket from subframe (arrows).
10. Separate exhaust system at clamp (arrows).
11. Raise exhaust pipe and secure.
12. Mark position of propshaft with flexible coupling relative to bevel box flange.
13. Unbolt propshaft with flexible coupling from bevel box flange (arrows).
14. Pull connector (1) off oil level and oil temperature sender G266.
15. Remove bolts (2) and (3) for pendulum support on gearbox. [Note: After pendulum support securing bolts are loosened, the engine/gearbox assembly will swing slightly forwards (towards front of car). Ensure that seal (arrow) in flange of propshaft is not damaged during removal or installation.]
16. Press gearbox/engine assembly forward slightly and then pull propshaft out of bevel box.
17. Raise propshaft and secure with wire.
18. Remove left and right coupling rods from anti-roll bar.
19. Unscrew nuts (arrows) for swivel joint and suspension links.
20. Fix position of subframe prior to removal Running gear, axles, steering40Subframe, anti-roll bar, suspension links; Fixing position of subframe and brackets.
21. Remove subframe Running gear, axles, steering40Subframe, anti-roll bar, suspension links; Removing and installing subframe.
22. Remove support (A) for exhaust manifold, if present 26Exhaust system.
23. If present, remove shield for right drive shaft from bevel box (arrows).
24. Remove right drive shaft from flange shaft of gearbox. Secure drive shaft to body using wire, taking care not to damaged surface protection.
25. Remove right flange shaft with socket T10107(arrow 1).
26. Remove support for turbocharger 21Assembly overview - turbocharger
27. Unbolt exhaust gas recirculation cooler but do not remove coolant hoses 26Assembly overview - exhaust gas recirculation cooler
28. Remove support for particle filter 26Parts of exhaust system; Assembly overview - front exhaust pipe with particle filter.
29. Remove particle filter 26Parts of exhaust system; Assembly overview - front exhaust pipe with particle filter
30. Remove bevel box carrier bolts from engine and bevel box (arrows 1), (arrows 2) and (arrow 3).
31. Remove bevel box carrier.
32. Remove lower securing bolts (arrows) for joining bevel box to gearbox.
33. Remove upper securing bolts for joining bevel box to gearbox.
34. Carefully press bevel box off gearbox, taking care that it does not fall.
35. Remove bevel box.
36. If bevel box is to be renewed, check whether heat shield (A) must be removed.

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