Bevel Box, Installing, Golf And Golf Wagon

Special tools and workshop equipment required

Engine Support :T50015
Holding Fixture - Gearbox Adapter :T10235

CAUTION:

This procedure contains mandatory replaceable parts. Refer to component overview and parts information prior to starting procedure.

Mandatory Replacement Parts

Seal - Bevel Box to Transmission
Bolts - Bevel Box to Transmission
Seal - Bevel Box
Bolt - Output Flange to Bevel Box

NOTE:

Refer to "Bevel Box, Removing" to get a list of the special tools needed. Refer to BEVEL BOX, REMOVING, GOLF AND GOLF WAGON .

Replace self-locking bolts 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 the reverse order of removal while noting the following:

-- Coat the splines on the manual transmission differential with Grease for Clutch Disc Shaft Splines.

-- Secure the :T50015 to the subframe using the M 8 x 25 collar bolt -A-.

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-- Secure the :T10235 for attaching the :T50015 in the rear threaded hole for the pendulum support on the transmission.

-B- = washer approximately 2 mm thick.

-- Push the engine/transmission forward while paying attention to the stop on the radiator.

-- Slide the bevel box as far as possible onto the manual transmission. While doing so, join the splines of input shaft/bevel box centrally with the differential.

-- With the proper tooth position and central guiding, the bevel box slides against the manual transmission.

The space to access the upper bevel box bolts on the manual transmission is narrow.

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Layout of the upper bevel box bolts (-1 and 2-) on the manual transmission (covered by the bevel box).

The bolt -1- is located near the bolt -A-.
The bolt -2- is located near the bolt with the threaded connection -B-.
The front exhaust pipe with the catalytic converter or the particulate filter -C- is located above the bolts.

NOTE:

Do not tighten the bevel box against the transmission with the bolts, otherwise the bevel box could tilt and the eyes could break off.

-- Tighten the upper and lower bevel box bolts -arrows- on the transmission using a commercially available socket. For the tightening specification. Refer to OVERVIEW - DIFFERENTIAL, AWD AND FWD WITH FRONT AXLE DIFFERENTIAL LOCK .

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The bevel box upper bolts -arrows a and b- to the manual transmission -1- are accessible from the engine compartment.

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-- If removed, install the EGR cooler. Refer to EXHAUST PIPES/MUFFLERS .

-- Fasten the flange shaft with a new bolt. Tightening specification. Refer to OVERVIEW - DIFFERENTIAL, AWD AND FWD WITH FRONT AXLE DIFFERENTIAL LOCK .

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-- Secure the bevel box transmission support to the engine and bevel box while pay attention to the tightening sequence for the bolts -1 and 2-. Refer to Fig 1.

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-- Remove the :T50015 .

-- Install the pendulum support with new bolts. Refer to OVERVIEW - SUBFRAME MOUNT .

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NOTE:

Threaded inserts (for example, "Heli Coil") are found in the pendulum support fastening holes on some transmissions. Refer to Figure.

-- When installing the pendulum support, position the driveshaft with the flexible disc on the bevel box flange.

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-- When positioning, make sure that the seal -arrow- in the centering bushing is not damaged.

-- Secure the driveshaft to the bevel box flange -arrows-. Tightening specification. Refer to DRIVESHAFT, REMOVING AND INSTALLING - 0D9 or DRIVESHAFT, REMOVING AND INSTALLING - 0D9, 0FB .

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-- Attach the heat shield -1-. Refer to DRIVESHAFT, REMOVING AND INSTALLING - 0D9 or DRIVESHAFT, REMOVING AND INSTALLING - 0D9, 0FB for the tightening specification.

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-- Assemble the exhaust system. Refer to EXHAUST PIPES/MUFFLERS .

-- Install the right drive axle. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

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-- Fill the bevel box with gear oil. Refer to GEAR OIL IN BEVEL BOX, FILLING .

-- Install the drive axle heat shield, if equipped, from the bevel box -arrows-. Refer to DRIVE AXLE .

The right drive axle heat shield is attached with two or three nuts.

-- Install the Heater Support Pump -V488-. Refer to OVERVIEW - ELECTRIC COOLANT PUMP .

-- Connect the connector -1- to the Oil Level Thermal Sensor -G266-.

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-- Install the noise insulation. Refer to NOISE INSULATION .

Tightening Specification and Sequence for 0AV and 0CN Bevel Box Transmission Support in Golf and Golf Wagon

Fig 1: Tightening Sequence for Bevel Box Bracket (0CN Transmission Support)

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Bolt allocation

Item	Bolt	Quantity
1	M10 x 55	2
2	M10 x 20	2

-- Tighten the bolts in steps as follows:

Step	Bolts	Tightening Specification
1.	All	Install all the way by hand
2.	-1-	40 Nm
3.	-2-	40 Nm