Bevel Box

WARNING: This page is about a different car, the 2008 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Used oil collection and extraction device VAG 1782
Socket and extended bit T10107

Removing

-- Lift the vehicle, all 4 lift points of the hoist must be at the same height.

-- Place the selector lever in the >>P<< position.

-- Remove the right front wheel.

-- Remove the noise insulation tray.

-- Remove the right drive axle heat shield bolts -arrows- and bolts from the bevel box.

Fig 1: Identifying Right Driveshaft Heat Shield And Bevel Box

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-- Remove the right drive axle from the transmission flange.

-- Lift up the right drive axle and secure with wire.

-- Remove the exhaust system suspended mount bolts -arrows-.

Fig 2: Identifying Bracket For Exhaust System

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-- Remove the bracket -2- for the oil level thermal sensor wire on the subframe.

Fig 3: Identifying Oil Level Thermal Sensor G266 Wire On Subframe

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-- Remove nuts -1- and bolts -2- for the bevel box bracket.

Fig 4: Identifying Bracket For Bevel Box & Bolts

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-- Remove the bracket -A- for bevel box.

-- Loosen the clamping sleeve nuts -arrows- and disconnect the exhaust system.

Fig 5: Identifying Exhaust System Double Clamp

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-- Use a chain to secure the exhaust system in position. To do this, insert the 3004 into the openings at vehicle floor (remove the plug, if necessary).

Fig 6: Identifying Chain To Tie Exhaust System In Position With Hooks -3004-

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-- Identify the position of the driveshaft flexible disc and bevel box flange to each other.

-- Remove the driveshaft flexible disc to bevel box bolts.

Fig 7: Identifying Bevel Gear Transfer Case Flange Bolts

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-- Press the driveshaft horizontally toward the rear as far as possible.

Fig 8: Identifying Sealing Ring In Driveshaft Flange

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CAUTION:

Sealing ring -arrow- in the driveshaft flange must not be damaged when removing the transmission. If the seal is damaged, the driveshaft must be replaced.
When loosening pendulum support/subframe bolts, the engine/transmission assembly moves forward slightly.

-- Remove the pendulum support bolts -2 and 3-.

Fig 9: Identifying Pendulum Support & Bolts

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-- Press the engine and transmission forward slightly and remove the drive shaft from the bevel box.

-- Lay the driveshaft above the bevel box and secure it against falling down.

-- Remove the subframe.

Fig 10: Identifying Subframe Secured On Engine/Transmission Jack V.A.G 1383 A With Accompanying Strap

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For removing the subframe, refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) BGP, BPY, AWP, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation . There is much useful information there. If done correctly, the subframe can be removed and installed without the customer experiencing increased tire wear later. It is recommended to read this information prior to removing the transmission. In this way, the subframe can be secured and removed correctly.

-- Place the VAG 1782 beneath the transmission.

-- Remove the right flange shaft bolt -arrow 1- using the T10107.

Fig 11: Identifying Right Flange Shaft Bolt

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-- Remove the four bevel box to transmission bolts.

-- Remove the bevel box together with the flange shaft from the transmission.

Installing

Installation is performed in the reverse order of removal. Pay attention to the following:

-- Place the bevel box together with the flange shaft to the transmission and rotate the flange shaft.

-- Secure the bevel box to the transmission with four new bolts.

Tightening Specifications

Bevel box to transmission bolts: 30 Nm

-- Position the bevel box bracket and install the nuts -1 and 2- hand tighten.

Fig 12: Identifying Bracket For Bevel Box & Bolts

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-- Observe the installation sequence:

Tighten the nuts -1- to 3 Nm.
Tighten the nuts -2- to 35 Nm.
Tighten the nuts -1- to 45 Nm.

-- Install the subframe. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) BGP, BPY, AWP, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation .

-- Press the engine/transmission assembly toward the bulkhead; while doing so, carefully guide the pin of the bevel box flange into the driveshaft flange.

-- Be careful of sealing ring.

Fig 13: Identifying Sealing Ring In Driveshaft Flange

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-- Secure the pendulum support to the transmission with new bolts -2 and 3-.

Fig 14: Identifying Pendulum Support & Bolts

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-- Install the exhaust system tension free. Refer to EXHAUST SYSTEM, INSTALLING .

-- Install the right drive axle. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) BGP, BPY, AWP, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation .

-- Check the oil level in the bevel box and top off. Refer to OIL FILTER, CHANGING AND OIL LEVEL, ADJUSTING .

Tightening Specifications

Component	Nm
Drive axle heat shield to bevel box	25