Overview - Bevel Box Components

(Seal, Stub Shaft Bearing, Output Flange in Bevel Box) 

Fig 1: Exploded View Of Bevel Box Components

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Left Outer Seal
   • Always replace after removing
   • Between the bevel box and the transmission
   • Remove to replace the bevel box. Refer to BEVEL BOX .
2. Left Inner Seal
   • Always replace after removing
   • Between the bevel box and the transmission
   • Remove to replace the bevel box. Refer to BEVEL BOX .
3. Plug
   • 15 Nm
   • Always replace after removing
   • With permanent seal
4. Cap
   • Drive in until stop using the Holding Fixture - Spacers: VW540/1B 
5. Right Seal
   • Always replace. Refer to RIGHT SEAL ON BEVEL BOX, REPLACING .
   • For the right stub shaft to the drive axle
   • The seal can be replaced with the bevel box installed
6. Bevel Box
   • Removing and installing. Refer to BEVEL BOX .
7. Cap
   • For bleeding the bevel box
8. Bleed Pipe
   • For bleeding the bevel box
   • Press it in all the way
9. Circlip
   • Always replace after removing
   • Insert in the groove all around the stub shaft
10. O-ring
    • Always replace after removing
    • Insert in the groove all around the stub shaft
11. Right Stub Shaft
    • Remove the bevel box to remove and install. Refer to BEVEL BOX .
    • Removing and installing. Refer to STUB SHAFT NEEDLE BEARING (POLYGON BEARING), REPLACING .
12. Needle Bearing (Polygon Bearing)
    • Always replace. Refer to STUB SHAFT NEEDLE BEARING (POLYGON BEARING), REPLACING .
    • The needle bearings (polygon bearings) are difficult to move when the stub shaft is removed. Difficulty in movement is not an indication of faulty bearings. An acoustic test can only be performed while installed.
    • Check for damage on the bearing, for example, cracks on outer race and replace if necessary.
13. Circlip
    • Always replace after removing.
    • For the needle bearing (polygon bearing)
    • Insert in the groove all around the stub shaft
14. Nut
    • 480 Nm
    • Always replace after removing.
    • Removing. Refer to Figure.
    • Install with Locking Compound: D 000 600  .
    • Installing. Refer to Figure.
15. Output Flange
    • Removing and installing. Refer to BEVEL BOX OUTPUT FLANGE SEAL, REPLACING (BEVEL BOX REMOVED) .
16. Cap
    • Always replace the output flange after removal if damaged
    • Not equipped for all bevel boxes
    • Lock with the output flange
17. Output Flange Seal
    • Always replace after removing
    • For the output flange
    • Remove to replace the bevel box. Refer to BEVEL BOX .
18. Bolt
    • 25 Nm
    • Tighten in a diagonal sequence
19. Pinion Housing
    • With shaft bevel gear and inner race/tapered roller bearing
    • Components are not replacement parts
    • Carefully pry out from side to side
    • Note the fastening holes; the pinion housing only fits in one position.
20. O-ring
    • Always replace after removing the pinion housing
    • To replace, remove the bolts -item  ) OVERVIEW - BEVEL BOX COMPONENTS - List Item: Bolt and carefully pry the pinion housing out at the tabs protruding all the way around.
    • Do not remove the hex nut -item  ) OVERVIEW - BEVEL BOX COMPONENTS - List Item: Nut and output flange -item  ) OVERVIEW - BEVEL BOX COMPONENTS - List Item: Output Flange.