Bevel Box, Installing, 0AV
Pay attention to "bevel box, differentiating". Refer to BEVEL BOX, DIFFERENTIATING .
Refer to "Bevel Box, Removing" to get a list of the special tools needed. Refer to BEVEL BOX, REMOVING, 0AV .
Replace self-locking screws and nuts after removing them.
Replace bolts that were tightened with an additional turn after removing them.
Install any cable ties that were loosened or cut off during removal at their same location.
Install in reverse order of removal. Note the following:
Install the bevel box with the flange shaft removed.
-- Coat the splines on the manual transmission differential with Grease For Clutch Disc Shaft Splines G 000 100.
-- Slide bevel box completely onto transmission. While doing this, join splines of input shaft/bevel box centrally with differential.
-- With proper tooth position and central guiding, bevel box slips up to stop against manual transmission.
Do not pull bevel box with mounting bolts against manual transmission, otherwise bevel box is canted and mounting eyelets can break off.
-- Install bevel box upper bolts (-arrows-) to the manual transmission and tighten. Refer to OVERVIEW - DIFFERENTIAL, AWD AND FWD WITH FRONT AXLE DIFFERENTIAL LOCK .
-- Install bevel box lower bolts (-arrows-) to the manual transmission and tighten. Refer to OVERVIEW - DIFFERENTIAL, AWD AND FWD WITH FRONT AXLE DIFFERENTIAL LOCK .
-- Attach the transmission support while paying attention to the tightening sequence of bolts -A- and -B-. Refer to Fig 7.
-- Install the turbocharger support -arrow-. Refer to [For engine(s) CCTA, CBFA] Turbocharger, Supercharger .
-- Install the right flange shaft carefully. Rotate the flange shaft while doing this to prevent damaging the bearing.
-- Tighten the flange shaft -item 13- OVERVIEW - DIFFERENTIAL, AWD AND FWD WITH FRONT AXLE DIFFERENTIAL LOCK => List Item:Bolt .
-- Fill the bevel box with gear oil. Refer to GEAR OIL IN BEVEL BOX, FILLING .
-- Install the right drive axle -C-. Refer to [For transmission(s) 02E, 02Q, 09M] [For engine(s) CNNA, CCTA, CBFA] Drive Axle Differentiation .
CC, Passat with Parking and Auxiliary Heater:
-- If present, install coolant pipes -B- on bevel box and engine -arrow 2-.
Continuation for All
-- Install the drive axle heat shield -A- -arrows 1- [For transmission(s) 02E, 02Q, 09M] [For engine(s) CNNA, CCTA, CBFA] Drive Axle Differentiation .
The heat shield for the right drive axle is attached with 2 or 3 nuts. Refer to [For transmission(s) 02E, 02Q, 09M] [For engine(s) CNNA, CCTA, CBFA] Drive Axle Differentiation .
-- Attach the driveshaft with the flexible disc to the bevel box flange -arrows-. Refer to [For transmission(s) 02E, 09M] Driveshaft .
Threaded inserts (for example, "Heli Coil") are found in the pendulum support fastening holes on some transmissions. Refer to Figure.
-- Install pendulum support with new bolts. Refer to [For transmission(s) 02E, 02Q, 09M] [For engine(s) CNNA, CCTA, CBFA] Front Suspension .
-- Install the particulate filter and attach the bracket for the exhaust system to the subframe. Refer to [For engine(s) CCTA, CBFA] Exhaust System, Emission Controls[For transmission(s) 09M] [For engine(s) CNNA] Exhaust System, Emission Controls .
-- Install the noise insulation. Refer to Noise Insulation .
There is transmission support under the turbocharger support -arrow-.
Allocation of bolts.
| Item | Bolt | Quantity |
|---|---|---|
| A | M10 x 21 | 2 |
| B | M10 x 45 | 2 |
-- Tighten the bolts in steps as follows:
| Step | Bolts | Tightening Specification |
|---|---|---|
| 1. | All | Install the bolt hand-tight. |
| 2. | -A- | 40 Nm |
| 3. | -B- | 40 Nm |