Overview - Bevel Box Components, "0AV"

(Seals, Flange Shaft Bearing, Output Flange Bearing inside the Bevel Box)

Fig 1: Exploded View Of Bevel Box Components (0AV)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Seal
   • Replace after removing
   • Between the bevel box and manual transmission
   • Replace with bevel box removed. Refer to SEAL BETWEEN BEVEL BOX AND MANUAL TRANSMISSION, REPLACING ON BEVEL BOX .
2. Bevel Box
   • Removing. Refer to the appropriate Service Information
   • Installing. Refer to the appropriate Service Information
   • Removing, Transmission Removed. Refer to Fig 2.
   • Installing, Transmission Removed. Refer to Fig 2.
3. Fluid Drain Plug
   • 15 Nm
   • Replace after removing
   • With permanent seal
4. Fluid Filler Plug
   • 15 Nm
   • Replace after removing
   • With permanent seal
5. Seal
   • Replace after removing
   • For the right flange shaft
   • Replacing on installed manual transmission with bevel box. Refer to RIGHT SEAL, REPLACING .
6. Bleed Pipe
   • For bleeding the bevel box
   • Press it in all the way
7. Cap
   • For bleeding the bevel box
8. Bleed Pipe
   • 10 Nm
   • Allocate according to the Parts Information.
9. Bolt
   • 5 Nm
10. Shield
    • Not equipped on all bevel boxes
    • The shape may look different than the illustration.
    • Allocate according to the Parts Information.
11. Right Flange Shaft
    • Removing and installing. Refer to RIGHT SEAL, REPLACING .
12. Seal
    • Replace after removing
    • To replace, remove the needle bearing (polygon bearing). Refer to NEEDLE BEARING (POLYGON BEARING) AND NEEDLE BEARING SEAL ON THE RIGHT FLANGE SHAFT, REPLACING .
13. Needle Bearing (Polygon Bearing)
    • The needle bearings (polygon bearings) are difficult to move when the flange 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.
    • Replacing. Refer to NEEDLE BEARING (POLYGON BEARING) AND NEEDLE BEARING SEAL ON THE RIGHT FLANGE SHAFT, REPLACING .
14. Circlip
    • Replace after removing
    • For the needle bearing (polygon bearing)
    • Insert in the groove all around the stub shaft
15. Nut
    • 480 Nm
    • Replace after removing.
    • Removing. Refer to Figure.
    • Install with Locking Fluid: D 000 600  .
    • Installing. Refer to Figure.
16. Output Flange
    • Replacing. Refer to OUTPUT FLANGE, REPLACING; OUTPUT FLANGE SHIM, REDETERMINING .
17. Cap
    • Not equipped on all bevel boxes
    • Replace if damaged
    • Allocate according to the Parts Information.
    • Lock with the output flange
18. Shim
    • When replacing the output flange, redetermine the thickness. Refer to OUTPUT FLANGE, REPLACING; OUTPUT FLANGE SHIM, REDETERMINING .
19. Seal
    • Replace after removing
    • For the output flange
    • Replace only when the bevel box is removed. Refer to BEVEL BOX OUTPUT FLANGE SEAL, REPLACING, "0AV" (BEVEL BOX REMOVED) .
20. Inner Race/Tapered Roller Bearing
    • The component is not a replacement part
21. Bolt
    • 25 Nm
22. Pinion Housing
    • With shaft bevel gear and outer 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.
23. O-Ring
    • To replace, remove the bolts and carefully pry the pinion housing out at the tabs protruding all the way around.
    • Do not remove the hex nut and output flange
24. Shim
    • The component is not a replacement part
    • Note the bevel box fastening holes; the shim only fits in one position
25. Cap
    • Drive in until stop using the Holding Fixture - Spacers: VW540/1B 

Fig 2: Identifying Removal/Installation Right Flange Shaft Countersunk Bolt Using Socket And Key T10107

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.