Bevel Box 0CN, Installing

NOTE:

Refer to "Bevel Box, Removing" to get a list of the special tools needed. Refer to BEVEL BOX 0CN, REMOVING .

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:

Push the engine/transmission toward the front and support the pendulum support as illustrated.

Fig 1: Identifying Collar Bolt And 3253/5

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-A- = M10 x 35 collar bolt

-- 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. If necessary, turn on the flange shaft.

-- With proper tooth position and central guiding, bevel box slips up to stop against manual transmission.

NOTE:

Do not pull bevel box with mounting bolts against manual transmission, otherwise bevel box can be tilted and mounting eyelets can break off.

-- Install the lower bolts (-arrows-) that attach the bevel box to the manual transmission and tighten to the specification -item 12- OVERVIEW - DIFFERENTIAL - List Item: Hex Bolt .

Fig 2: Identifying Bevel Box To Transmission Bottom Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the flange shaft -item 13- OVERVIEW - DIFFERENTIAL - List Item: Bolt .

Fig 3: Identifying Right Flange Shaft Countersunk Bolt, Socket And Key T10107

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Attach the transmission support while paying attention to the tightening sequence of bolts -1 and 2-. Refer to Fig 11.

Fig 4: Bevel Box Transmission Support Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the Heater Support Pump -V488-. Do not open the system. Connect the connectors. Refer to OVERVIEW - ELECTRIC COOLANT PUMP .

NOTE:

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

Fig 5: Identifying Pendulum Support

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

-- Attach the driveshaft with the flexible disc to the bevel box flange -arrows-. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

Fig 6: Driveshaft Flexible Disc

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Attach heat shield -1- -arrows-. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

Fig 7: Identifying Heat Shield

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 8: Identifying Right Drive Axle Heat Shield

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- If removed, install the drive axle heat shield -arrows-. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

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

Fig 9: Locating Bevel Box Upper Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the upper bolts (-arrows-) that attach the bevel box to the manual transmission and tighten to the specification -item 12- OVERVIEW - DIFFERENTIAL - List Item: Hex Bolt .

Fig 10: Identifying Bevel Box To Transmission Top Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install EGR cooler. Refer to Exhaust System, Emission Controls .

-- Assemble the exhaust system. Refer to OVERVIEW - MUFFLER .

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

Tightening Specification and Sequence for Bevel Box 0CN Transmission Support

Fig 11: Bevel Box Transmission Support Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Allocation of bolts.

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 the bolt hand-tight.
2.	-1-	40 Nm
3.	-2-	40 Nm