Bevel Box, Removing

Special tools and workshop equipment required

Hex Ball Socket:3247

Fig 1: Identifying Hex Ball Socket 3247
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Socket and Extended Bit:T10107 A

Fig 2: Identifying Socket And Extended Bit
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Counterhold - Multiple Use:T10172A

Fig 3: Counterhold - Kit - Multiple Use T10172
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Engine Support:T50015A

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Engine Support - Bracket:T10533/2

Fig 4: Engine Support : T10533
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Engine Support - Bolt:T10533/4
Torque Wrench 1331 5-50Nm:V.A.G 1331

Fig 5: Identifying Torque Wrench
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M8 x 30 Collar Bolt
Grease for Clutch Plate Shaft Splines. Refer to Parts Information.

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

Fig 6: Identifying Left Front Drive Axle Bolt

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-- 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 .

NOTE:

To make it possible to rotate the driveshaft later so it can be loosened:

-- Move the selector lever into >>N<<.

-- Remove the noise insulation below the engine/transmission. Refer to Noise Insulation .

-- Release and remove the connector -1- from the Oil Level Thermal Sensor -G266-.

Fig 7: Disconnecting Connector From Oil Level Thermal Sensor G266

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

-- If equipped, remove the drive axle heat shield -1- from the bevel box -arrows-. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

Fig 8: AWD:

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CAUTION:

Risk of damaging the decoupling element.

Pay attention to OVERVIEW - EMISSIONS CONTROL SYSTEM, FWD or OVERVIEW - EMISSIONS CONTROL SYSTEM, AWD .

-- Remove the front exhaust system from the engine and tie up. Refer to OVERVIEW - MUFFLER, PASSAT, ARTEON .

Remove the driveshaft heat shield, if equipped.

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

Fig 9: Driveshaft Heat Shield

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

Fig 10: Mark Position Of Driveshaft

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

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-- Use the Adapter:T10172/5- -1- and the Counterhold Tool:T10172 -2- to loosen and tighten.

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NOTE:

To loosen the >>next<< bolt, at the same time rotate the driveshaft by turning the rear wheels.

-- Remove the pendulum support bolts -1- from the transmission.

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-- Place a cloth on the subframe to prevent damaging the paint on the driveshaft when it will be placed on it.

To remove the driveshaft from the alignment pin on the bevel box the >>transmission<< must be pushed slightly forward. When pushing into place, make sure that the seal -1- in the centering bushing is not damaged.

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-- Press the pendulum support to the side.

-- Bolt down the Bracket:T10533/2 -A- with the Engine Support:T50015 -B-. To do this, use an M8 x 30 bolt -1-.

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-- Tighten the Bracket -A- to the Bolt:T10533/4 -C- on the transmission.

-- Tighten the Engine Support -B- to the subframe, using an M8 bolt.

-- Tighten the bolts hand-tight.

-- Push the engine forward as far as possible using the Engine Support:T50015A .

-- Make sure the coolant hoses are not clamped between the engine and the radiator.

-- Remove the driveshaft from the bevel box and place it on the subframe.

Vehicles with Gasoline Engine

Fig 11: Transmission Support to Engine and Bevel Box

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

NOTE:

The next illustration shows the bevel box with the stub shaft instead of the flange shaft.

Vehicles with diesel engines

Fig 12: Bracket Version 1 for Bevel Box

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-- Remove the bolts -A and B- and remove the bevel box transmission support -1-.

-- Remove the bolt for the right flange shaft using the Socket and Extended Bit: T10107A .

Fig 13: Removing The Countersunk Bolt Using T10107A

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-- Insert two bolts in the flange and counterhold the flange shaft with the tire iron.

Fig 14: Identifying Right Flange Shaft Countersunk Bolt, Socket And Key T10107

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Replace the countersunk bolt after removing.

-- Remove the upper bolts -arrows- that attach the bevel box to the transmission.

Fig 15: Identifying Bevel Box Bolts

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-- Remove the lower bolts -arrows- and the bevel box.

-- Install the bevel box. Refer to BEVEL BOX, INSTALLING .