Bevel Box, Removing, Golf And Golf Wagon

Special tools and workshop equipment required 

• Hex Ball Socket :3247 
• Socket And Extended Bit :T10107A 
• Counter hold - Multiple Use :T10172A 
• Spindle Cover :T10381 
• Torque Wrench 1331 5-50Nm :VAG1331 
• Engine Support :T50015A 
• Holding Fixture - Gearbox Adapter :T10235 
• Not needed: Engine Support Device - Gearbox Bracket :T10346/1 
• Golf: M 8 X 25 bolt

The right drive axle must be removed later in the procedure.

-- With the vehicle still standing on its wheels, loosen the front collar bolt -arrow- a maximum of 90°. Otherwise the wheel bearing will be damaged. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

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

-- Disconnect the connector -1- from the Oil Level Thermal Sensor -G266-.

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Golf with Turbo Diesel Engine

-- Disconnect the connector from the Heater Support Pump -V488-. Refer to OVERVIEW - ELECTRIC COOLANT PUMP .

-- Remove the Heater Support Pump -V488- from the engine and push it to the right. Do not open the system while doing this. Refer to OVERVIEW - ELECTRIC COOLANT PUMP .

Continuation for All

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-- Remove the drive axle heat shield -1-, if equipped, from the bevel box -arrows-. Refer to DRIVE AXLE .

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

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

-- Disconnect the exhaust system behind the particulate filter and tie it up. Refer to EXHAUST PIPES/MUFFLERS .

-- Remove the bolts -arrows- from the bevel box and remove the heat shield -1-.

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-- Mark the position of the driveshaft -arrows- with flexible disc to the bevel box output flange.

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-- Remove the front of the driveshaft from the bevel box -arrows-.

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-- If necessary, counterhold at the rear final drive to loosen and tighten the driveshaft.

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-- Place a cloth on the subframe to prevent damaging the paint on the driveshaft.

-- Push the front driveshaft all the way back. Make sure that the seal -arrow- in the centering bushing is not damaged.

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-- Place the front of the driveshaft on the heat shield or on the subframe if necessary.

-- Remove the pendulum support. Refer to OVERVIEW - SUBFRAME MOUNT .

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-- 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.

-- Push the engine/transmission as far forward as possible by turning the spindle for the :T50015  . Avoid bumping the fan shroud with other components.

-- Remove bolts -1 and 2- and bevel box transmission support.

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-- Remove the bolt for the right flange shaft using the :T10107A  .

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-- Insert two bolts in the flange and counterhold the flange shaft with the pry lever.

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Replace the countersunk bolt after removing.

For EGR Cooler

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-- Remove the EGR cooler if necessary. Refer to EXHAUST PIPES/MUFFLERS .

Continuation for All

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

-- Loosen the bolt -arrow a- with the 8 X 50 inner hex socket; loosen the bolt -arrow b- with the 8 X 20 inner hex socket.

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.

-- Remove the upper bevel box bolts -1 and 2- on the manual transmission.

-- Remove the lower bevel box bolts -arrows- on the manual transmission.

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-- Carefully push the bevel box off the manual transmission and remove it.

-- Rotate the bevel box when removing it so that it does not tilt at the engine and subframe.

-- Insert the Closure Cap in the manual transmission.

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