Bevel gear transfer case, removing and installing (vehicles with 6-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 under 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

GW00001790

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt driveshaft with flexible disc from bevel gear transfer case flange - arrows -.
Remove shielding plate for drive axle on right side, if installed.
Disconnect right drive axle from transmission.
Tie up drive axle as far out of way as possible. This ensures that drive axle paint is not damaged.

Separate exhaust system at double clamp → 26 - EXHAUST SYSTEM, EMISSION CONTROLS .

Fig 2: Identifying Pendulum Support On Subframe

GW00001811

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 3: Identifying Guide Pin For Driveshaft

GW00001795

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

NOTE:

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

Fig 4: Identifying Engine & Bevel Gear Transfer Case Bolts

GW00001802

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove transmission carrier for bevel gear transfer case from engine and bevel gear transfer case - arrows -.
Place drip tray underneath transmission and engine.

Fig 5: Identifying Oil Drain Plug

GW00001812

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Press bevel gear transfer case from transmission.
Remove bevel gear transfer case.