Bevel Box, Removing

Special tools and workshop equipment required 

• Socket and Extended Bit: T10107 A 
  Fig 1: Identifying Socket And Extended Bit

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• Counterhold - Multiple Use: T10172A 
  Fig 2: Counterhold - Kit - Multiple Use T10172

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• Spindle Cover: T10381 

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• Engine Support: T50015A 

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• Holding Fixture - Gearbox Adapter: T10235 
  Fig 3: Identifying Gearbox Adapter

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

-- With the vehicle still standing on its wheels, loosen the front collar bolt -arrow- a maximum 90°, otherwise the wheel bearing will get damaged. Refer to the appropriate Service Information .

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

-- Disconnect the connector -1- from the Oil Level Thermal Sensor -G266-.

Continuation for All 

-- Remove the drive axle heat shield -1-, if equipped, from 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.

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

-- Disconnect the exhaust system behind the particulate filter and tie it up. Refer to OVERVIEW - MUFFLER, GOLF FWD .

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

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

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

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-- If necessary, counterhold at the rear final drive to loosen and tighten the driveshaft.

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

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-- Push the front driveshaft all the way back. Make sure that the seal -arrow- in the centering bushing is not damaged.

-- Place the front driveshaft on the heat shield or on the subframe, if necessary.

-- Remove the pendulum support. Refer to PENDULUM SUPPORT, REMOVING AND INSTALLING .

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

-- Secure the Holding Fixture - Gearbox Adapter: T50015A  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.

-- Push the engine/transmission as far forward as possible by turning the spindle for the Engine Support: T50015A  . Avoid bumping the fan shroud with other components.

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

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

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

Replace the countersunk bolt after removing.

For EGR cooler 

-- Remove the EGR cooler, if necessary. Refer to the appropriate Service Information .

Continuation for All 

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

-- Loosen the bolt -arrow a- with the 8 X 50 inner hex socket; loosen the bolt -arrow b- with the 8 X 20 inner hex socket.

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.

-- Remove the upper bevel box bolts -5- and -2- on the manual transmission.

-- Remove the lower bevel box bolts -arrows- on the manual transmission.

-- Carefully push the bevel box off the manual transmission and remove it.

-- Rotate the bevel box when removing it so that it does not tilt at the engine and subframe.

-- Insert the Spindle Cover in the manual transmission.