Bevel Box, Installing

NOTE:

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

Replace self-locking bolts and nuts after removing them.

Replace the 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 Plate Shaft Splines.

-- Secure the Engine Support: T50015A to the subframe using the M8 x 25 collar bolt -A-.

Fig 1: Identifying Engine Support and Gearbox Adapter

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-- Secure the Holding Fixture - Gearbox Adapter: T10235 for attaching the Engine Support: T50015A 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 (-2- and -5-) on the manual transmission (covered by the bevel box).

-A- Inner hex socket with joint head, 8 mm
The bolt -1- is an upper connecting bolt for the bevel box with threaded pin, in direction of travel to the rear
The bolt -2- is an upper connecting bolt for the bevel box to the manual transmission, in direction of travel to the rear.
The front exhaust pipe with the catalytic converter or the particulate filter is located -3- above the bolts.
The bolt -4- is an upper connecting bolt in the bevel box, in direction of travel to the front.
The bolt -5- is an upper connecting bolt for the bevel box to the manual transmission, in direction of travel to the front.

CAUTION:

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 .

Fig 2: Identifying Bevel Box Bolts

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

Fig 3: Locating Bevel Box Upper Bolts

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-- If removed, install the EGR cooler. Refer to the appropriate Service Information .

-- Fasten the flange shaft with a new bolt. Tightening specification. Refer to OVERVIEW - DIFFERENTIAL .

Fig 4: Removing The Countersunk Bolt Using T10107A

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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 10.

Fig 5: Bevel Box Transmission Support

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-- Install the Engine Support: T50015A .

-- Install the pendulum support with new bolts. Refer to OVERVIEW - ASSEMBLY MOUNTS .

Fig 6: Identifying Pendulum Support

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CAUTION:

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 the appropriate Service Information .

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-- Attach the heat shield -1-. Refer to the appropriate Service Information for the tightening specification.

Fig 7: Identifying Heat Shield

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-- Assemble the exhaust system. Refer to OVERVIEW - MUFFLER, GOLF FWD .

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

Fig 8: Identifying Heat Shield Nuts

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

-- If equipped, install the drive axle heat shield -1- on the bevel box -arrows-. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

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-.

Fig 9: Disconnecting Connector From Oil Level Thermal Sensor G266

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

Tightening Specification and Sequence for Bevel Box Transmission Support

Fig 10: Bevel Box 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