Bevel Box, Removing

Special Tools And Workshop Equipment Required 

• Hex Ball Socket:3247 
• Socket And Extended Bit:T10107A 
• Counterhold - Multiple Use:T10172A 
• Spindle Cover:T10381 
• Torque Wrench 1331 5-50 Nm :VAG1331 
• Engine Support:T50015A 
• Holding Fixture - Gearbox Adapter:T10235 
• M8 X 25 bolt

The right drive axle must be removed later in the procedure.

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-- With the vehicle still standing on its wheels, loosen the front collar bolt -arrow- a maximum 90°, otherwise the wheel bearing will get damaged. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- Disconnect the connector -1- from the Oil Level Thermal Sensor -G266-.

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Vehicles With Diesel Engines 

-- Disconnect the connector from the Heater Support Pump -V488- -1-.

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-- Remove the bolt -2- and push the Heater Support Pump -V488- to the right. Do not open the system while doing this. Refer to OVERVIEW - ELECTRIC COOLANT PUMP [FOR ENGINE(S) CNSB, CNSA, CXBB, CXBA, CXCB, CXCA] and OVERVIEW - ELECTRIC COOLANT PUMP [FOR ENGINE(S) CRUA] .

Continuation For All 

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-- If available, remove the drive axle heat shield from the bevel box -arrows-. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

The right drive axle heat shield is attached with two or three nuts.

-- Remove the right drive axle. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

Vehicles With Diesel Engines 

-- Remove the lock washer -2- from the front exhaust pipe. Refer to FRONT EXHAUST PIPE, REMOVING AND INSTALLING [FOR ENGINE(S) CRUA] and OVERVIEW - MUFFLER [FOR ENGINE(S) CNSB, CNSA, CXBB, CXBA, CXCB, CXCA] .

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Ignore bolts -1-.

Vehicles With Gasoline Engine 

-- Remove the front exhaust system from the engine and tie up. Refer to EXHAUST SYSTEM, INSTALLING WITHOUT TENSION [FOR ENGINE(S) CRUA] and EXHAUST SYSTEM, INSTALLING WITHOUT TENSION [FOR ENGINE(S) CNSB, CNSA, CXBB, CXBA, CXCB, CXCA] .

For All Vehicles: 

-- Remove the bolts -arrows- from the bevel box and remove the heat shield -1-.

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-- Mark the position of the driveshaft -arrows- with flexible disc to the bevel box output flange.

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-- Remove the front of the driveshaft from the bevel box -arrows-.

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-- If necessary, counterhold at the rear final drive to loosen and tighten the driveshaft.

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-- Place a cloth on the subframe to prevent damaging the paint on the driveshaft when it will be placed on it.

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-- Push the front driveshaft all the way back. Make sure that the seal -arrow- in the centering bushing is not damaged.

-- Place the front of the driveshaft on the heat shield or on the subframe if necessary.

-- Remove the pendulum support. Refer to PENDULUM SUPPORT, REMOVING AND INSTALLING .

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-- Secure the :T50015  to the subframe using the M 8 x 25 collar bolt -A-.

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-- Secure the :T10235  for attaching the :T50015  in the rear threaded hole for the pendulum support on the transmission.

-B- = washer approximately 2 mm thick.

-- Push the engine/transmission forward while paying attention to the stop on the radiator.

-- Push the engine/transmission as far forward as possible by turning the spindle for the :T50015A  . Avoid bumping the fan shroud with other components.

Vehicles With Diesel Engine And 1.4L Gasoline Engine 

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-- Remove bolts -1 and 2- and bevel box transmission support.

The transmission support for the 1.4L gasoline engine is similar to the transmission support in the image.

Vehicles With 1.8L And 2.0L Gasoline Engine 

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-- Remove bolts -1 and 2- and bevel box transmission support.

Continuation For All 

-- Remove the bolt for the right flange shaft using the :T10107A  .

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-- Insert two bolts in the flange and counterhold the flange shaft with the pry lever.

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Replace the countersunk bolt after removing.

Vehicles With EGR Cooler 

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-- Remove the EGR cooler if necessary. Refer to EGR COOLER, REMOVING AND INSTALLING .

Continuation For All 

The bevel box upper bolts -arrows a and b- to the manual transmission -1- are accessible from the engine compartment.

-- Loosen the bolt -arrow a- with the 8 X 50 inner hex socket; loosen the bolt -arrow b- with the 8 X 20 inner hex socket.

The space to access the upper bevel box bolts on the manual transmission is narrow.

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Layout of the upper bevel box bolts -1 and 2- on the manual transmission (covered by the bevel box).

• The bolt -1- is located near the bolt -A-.
• The bolt -2- is located near the bolt with the threaded connection -B-.
• The front exhaust pipe with the catalytic converter or the particulate filter -C- is located above the bolts.

-- Remove the upper bevel box bolts -1 and 2- on the manual transmission.

-- Remove the lower bevel box bolts -arrows- on the manual transmission.

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-- Carefully push the bevel box off the manual transmission and remove it.

-- Rotate the bevel box when removing it so that it does not tilt at the engine and subframe.

-- Insert the Closure Cap in the manual transmission.

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