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Home >> Volkswagen >> 2000 >> Golf GLS, 1.8 B, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 84 (6 SPD. Manual Transmission 02Y All Wheel Drive) >> 34 - Manual Transmission - Controls, Housing >> Bevel gear transfer case, removing and installing >> Bevel gear transfer case, removing and installing (vehicles with 4-cylinder engine) >> Installing

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

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.

Installation is the reverse of removal, noting the following:

NOTE:
  • Always replace and lightly oil O-ring for sealing bevel gear transfer case/manual transmission - arrow A  - and O-ring for sealing sleeve for oil supply - arrow B  - and - arrow C  -.
    • Fig 1: Identifying O-Ring For Sealing Bevel Gear Transfer Case/Manual Transmission & O-Ring For Sealing Sleeve For Oil Supply
    GW00001813Courtesy of VOLKSWAGEN UNITED STATES, INC.
  • Slide bevel gear transfer case completely onto manual transmission and join splines of input shaft/bevel gear transfer case centrally with sleeve/differential.
  • Bring right axle shaft splines and differential bevel gear into alignment; rotate flanged shaft if necessary.
  • With proper tooth position and central guiding, bevel gear transfer case slips up to stop against manual transmission.
  • Insert transmission carrier for bevel gear transfer case before installing connecting bolts for bevel gear transfer case/transmission.
  • Do not pull bevel gear transfer case against manual transmission with mounting bolts, otherwise bevel gear transfer case is canted and mounting eyelets can break off.
  • Sealing rings in driveshaft flanges must not be damaged when removing and installing.
  • Replace driveshaft if damaged.
  • Slide driveshaft on guide pin horizontally.
  • Replace seal for drive axle, if installed → 40 FRONT SUSPENSION .
  • Connect oil return line for turbocharger and vacuum diaphragm for charge pressure regulator valve to 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) .
  • Install exhaust pipe 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) .
  • Check gear oil in manual transmission with bevel gear transfer case → Gear oil, checking  .
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