Bevel Box, Removing

Special tools and workshop equipment required

Slide Hammer Set :VW771
Hex Ball Socket :3247
Holding Fixture - Spacers :VW540/1B
Puller - Bevel Gear :T10472
Counterhold - Multiple Use :T10172A
Engine Support :T10533

-- Lift the vehicle, all four mounts from lifting platform at the same height.

-- Turn the steering to the center position.

-- Move the selector lever to >>P<<.

NOTE:

Do not lower the vehicle onto the floor after loosening the central screw.

-- Press the brakes and loosen the bolt on the right drive axle -arrow- (a second technician is needed). Refer to DRIVE AXLE, REMOVING AND INSTALLING .

Fig 1: Identifying Left Front Drive Axle Bolt

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NOTE:

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

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

-- Remove the engine cover.

-- Remove the noise insulation below the engine/transmission. Refer to OVERVIEW - NOISE INSULATION .

-- Remove the connecting hose between the charge air cooler and the charge air pipe. Refer to OVERVIEW - CHARGE AIR SYSTEM .

Fig 2: Identifying Hose And Clamps

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

-- If equipped, disconnect the connector -1- from the sensor for the Oil Level Thermal Sensor -G266-.

Fig 3: Disconnecting Connector From Oil Level Thermal Sensor G266

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-- Remove the drive axle heat shield -1-, if equipped, from the bevel box (-arrows-). Refer to Drive Axle .

Fig 4: AWD:

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CAUTION:

There is a risk of damaging the exhaust system decoupling element.

- The decoupling element in the front exhaust pipe must not be stretched or kinked more than 10°.

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

If equipped, remove the driveshaft heat shield.

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

Fig 5: Driveshaft Heat Shield

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

Fig 6: Mark Position Of Driveshaft

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

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-- Counterhold the rear final drive to loosen and tighten the driveshaft.

Fig 7: Counterholding Rear Final Drive To Loosen And Tighten Driveshaft

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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.

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

Fig 8: Identifying Driveshaft Flange Shaft Seal

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

-- Mount the :T10533 as shown and tighten the bolts hand-tight.

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-A- flat side
-B- high side

Bolt -3- = original pendulum support bolt

-- Tighten an M8 x 30 mm bolt -1- with a washer -2- in the threaded hole for the noise insulation.

The transmission must be pushed slightly forward to tighten the :T10533 .

-- Push the engine/transmission as far forward as possible by turning the spindle for the :T10533 . Avoid bumping the fan shroud with other components.

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

Fig 9: Transmission Support To Engine And Bevel Box (Vehicles with 2.0L - 162-175 kW Engine)

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-- Remove the top of the bevel box from the transmission -arrows-.

Fig 10: Identifying Bevel Box To Transmission Top Bolts

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-- Only loosen the lower bolts for the bevel box on the transmission and loosen to the dimension -a-.

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Dimension -a- = 15 mm.

This prevents the bevel box from falling immediately when loosening with the :VW771 .

-- Install the :T10472 on the bevel box.

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-- Prepare the :VW771 with a washer -a- and two sleeves from the :VW540/1B as shown.

Fig 11: Complete The Slide Hammer Set VW771 Using The Holding Fixture - Spacers VW540/1B.

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-- Attach the :VW771 to the :T10472 and loosen the bevel box from the transmission.

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-- Remove the :VW771 and :T10472 from the bevel box.

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

Fig 12: Identifying Bevel Box To Transmission Bottom Bolts

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