Bevel gear transfer case, removing and installing (vehicles with 6-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 reverse of removal, note the following:
NOTE:
- Always replace and lightly oil O-ring for sealing bevel gear transfer case/manual transmission - arrow A - and O-ring of sealing sleeve for oil supply - arrow B - and - arrow C -.
- Slide bevel gear transfer case completely on manual transmission and join splines of input shaft/bevel gear transfer case with connecting 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 using 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 .
- Install exhaust pipe at double clamp → 26 - EXHAUST SYSTEM, EMISSION CONTROLS .
- Check gear oil in manual transmission with bevel gear transfer case → Gear oil, checking .
Fig 1: Identifying O-Ring For Sealing Bevel Gear Transfer Case/Manual Transmission & O-Ring For Sealing Sleeve For Oil Supply
- Install drive axles on transmission → 40 FRONT SUSPENSION .