Bevel gear transfer case, removing and installing (vehicles with 4-cylinder engine): Removing

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Remove sound insulation on bottom of engine/transmission, if installed.
Mark position of driveshaft with flexible disc to bevel gear transfer case flange.

Fig 1: Identifying Bevel Gear Transfer Case Flange Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt driveshaft with flexible disc from bevel gear transfer case flange - arrows -.
Remove charge air pipe between charge air cooler and turbocharger → 21 - TURBOCHARGER, G-CHARGER for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM) and 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) .
Remove right drive axle → 40 FRONT SUSPENSION .
Separate exhaust system at double clamp → 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM), 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) and 26 EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 2V ENGINE MECHANICAL, FUEL INJECTION & IGNITION, ENGINE CODE(S): AEG, AVH, AZG, BBW, BEV (A4 PLATFORM) .

Fig 2: Identifying Pendulum Support On Subframe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove pendulum support from subframe - arrows A -.
Carefully push engine/transmission toward front.

Fig 3: Identifying Guide Pin For Driveshaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Carefully pull off driveshaft tube at front from centering pin - arrow -.

NOTE:

Sealing ring in driveshaft flange must not be damaged when removing and installing.

Fig 4: Identifying Vacuum Diaphragm & Oil Return Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unscrew vacuum diaphragm - 1 - for charge pressure regulator valve from turbocharger - arrows - and tie up → 21 - TURBOCHARGER, G-CHARGER for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM) and 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) .
Place drip tray underneath transmission and engine.

Fig 5: Engine & Bevel Gear Transfer Case Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt oil return line - 2 - for turbocharger from engine → 21 - TURBOCHARGER, G-CHARGER for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM) and 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) .
Unscrew transmission carrier for bevel gear transfer case from engine and bevel gear transfer case, bolts - A - , - B - and bolt - C -.

NOTE:

Transmission carrier can only be removed when bevel gear transfer case has been pulled off of transmission.

If installed, remove turbocharger bracket → 21 - TURBOCHARGER, G-CHARGER for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM) and 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) .
Place drip tray underneath transmission and engine.

Fig 6: Identifying Oil Drain Plug

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove oil drain plug - arrow A -.
Drain gear oil from bevel gear transfer case.
Remove bolt for right drive shaft using socket V.A.G 1669/ or socket insert 6 mm (commercially available) - arrow -.
Remove connecting bolts for bevel gear transfer case/manual transmission.

Press bevel gear transfer case from manual transmission.
Remove transmission carrier for bevel gear transfer case.
Remove bevel gear transfer case.