Overview - Bevel Box Components: Notes

WARNING: This page is about a different car, the 2017 Volkswagen GTI, 2016 Volkswagen GTI, 2015 Volkswagen Golf, and 2015 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

Gaskets, Flange Shaft Bearing, Output Flange Bearing in the Bevel Box

Fig 1: Exploded View Of Bevel Box Components

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Seal
- Replace after removing
- Between bevel box and manual transmission
- Replacing. Refer to SEAL BETWEEN BEVEL BOX AND MANUAL TRANSMISSION, REPLACING .
Bevel Box
- Removing. Refer to BEVEL BOX, REMOVING .
- Installing. Refer to BEVEL BOX, INSTALLING .
- Removal for vehicles with removed transmission. Refer to Figure
- Installation for vehicles with removed transmission. Refer to Figure
Oil Drain Plug
- 15 Nm
- Replace after removing
- With permanent seal
Oil Filler Plug
- 15 Nm
- Replace after removing
- With permanent seal
Seal
- Replace after removing
- For the right flange shaft
- Replacing. Refer to RIGHT SEAL, REPLACING, AWD .
Bleed Pipe
- For bleeding the bevel box
- Press it in until it stops
Cap
- For bleeding the bevel box
Right Flange Shaft
- Removing and installing. Refer to RIGHT SEAL, REPLACING, AWD .
Seal
- Replace after removing
- Remove to replace needle bearing (polygon bearing). Refer to NEEDLE BEARING (POLYGON BEARING) AND NEEDLE BEARING SEAL ON THE RIGHT FLANGE SHAFT, REPLACING .
Needle Bearing (Polygon Bearing)
- The needle bearings (polygon bearings) are difficult to move when the flange shaft is removed. Difficulty in movement is not an indication of faulty bearings. A test for noisy bearings can only be performed with the bearings installed.
- Check for damage on the bearing, for example, cracks on outer race, replace if necessary.
- Replacing. Refer to NEEDLE BEARING (POLYGON BEARING) AND NEEDLE BEARING SEAL ON THE RIGHT FLANGE SHAFT, REPLACING .
Circlip
- Replace after removing
- For the needle bearing (polygon bearing)
- Insert in the groove running around the stub shaft
Twelve-Point Nut
- 350 Nm + 15 Nm
- Replace after removing.
- Removing. Refer to Figure.
- Install with Locking Fluid
- Installing. Refer to Figure.
- Cover nut on 3 opposite sides with peen
Output Flange
- Replacing. Refer to OUTPUT FLANGE, REPLACING; OUTPUT FLANGE SHIM, REDETERMINING .
Shim
- Determining the thickness when replacing the output flange. Refer to OUTPUT FLANGE, REPLACING; OUTPUT FLANGE SHIM, REDETERMINING
Seal
- Replace after removing
- For output flange
- Replacing. Refer to BEVEL BOX OUTPUT FLANGE SEAL, REPLACING .
Inner Race / Tapered Roller Bearing
- component is not a replacement part
Bolt
- 38 Nm
Pinion Housing
- With shaft bevel gear and outer race/tapered roller bearing
- Components are not replacement parts
- Carefully pry out from side to side
- Note the fastening holes; the pinion housing only fits in one position
O-ring
- To replace, remove the bolts and carefully pry the pinion housing out at the tabs protruding all the way around.
- Do not remove the hex nut and output flange
Shim
- Component is not a replacement part
- Note the bevel box fastening holes; the shim only fits in one position
Cap
- Drive in until stop using the :VW540/1B