Bevel Box, Removing: Removing

-- 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<<.

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- (second technician). 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 under the engine/transmission. Refer to the appropriate service information .

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

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

Fig 2: Disconnecting Connector From Oil Level Thermal Sensor G266

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-- Remove the nuts -arrows- and remove the right drive axle heat shield.

Fig 3: AWD:

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

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 catalytic converter and tie it up. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- If equipped, remove the driveshaft heat shield.

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

Fig 4: Driveshaft Heat Shield

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

Fig 5: 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.

-- Use the Adapter :T10172/5 -1- and the Counterhold - Multiple Use :T10172A 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 damage to the paint on the driveshaft when it is placed on the subframe.

-- Push the front driveshaft all the way back. Make sure that the seal -1- in the centering bushing is not damaged.

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

-- Mount the Engine Support :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 Engine Support :T10533 .

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

-- Remove the bevel box transmission support.

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

Fig 6: Transmission Support To Engine And Bevel Box (Vehicles With 2.0L - 162-175 KW Engine)

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-- Remove the upper bolts -arrows- from the bevel box -1-.

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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 immediately falling when loosening with the Slide Hammer Set :VW 771 .

-- Install the Puller - Bevel Gear :T10472 on the bevel box.

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-- Prepare the Slide Hammer Set :VW 771 with a washer -a- and two sleeves from the Holding Fixture - Spacers :VW 540/1 B as shown.

Fig 7: Complete The Slide Hammer Set VW771 Using The Holding Fixture - Spacers VW540/1B.

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-- Attach the Slide Hammer Set :VW 771 to the Puller - Bevel Gear :T10472 and detach the bevel box from the transmission.

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-- Remove the Slide Hammer Set :VW 771 and Puller - Bevel Gear :T10472 from the bevel box.

-- Remove the lower bolts -arrows- and remove the bevel box -1-.

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