Bevel Box, Removing

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Special tools and workshop equipment required 

• Hex Ball Socket: 3247 
• Socket and Extended Bit: T10107A 
• Counterhold - Multiple Use: T10172A 
• Spindle Cover: T10381 
• Torque Wrench, 6-50Nm: VAG1331A 
• Engine Support: T50015A 
• Holding Fixture - Gearbox Adapter: T10235 
• Not needed: Engine Support Device - Gearbox Bracket: T10346/1 
  Fig 1: Identifying Gearbox Adapter

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• M8 X 25 bolt

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

-- 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-.

Vehicles with diesel engines 

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

-- 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 .

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 OVERVIEW - MUFFLER .

Ignore the bolts -1-.

Vehicles with Gasoline Engine 

-- Remove the front exhaust system from the engine and tie up. Refer to OVERVIEW - MUFFLER .

For all vehicles: 

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

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

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

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

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

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

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

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

-- Secure the Engine Support: T50015  to the subframe using the M8 x 25 collar bolt -A-.

-- Secure the Holding Fixture - Gearbox Adapter: T10235  for attaching the Engine Support: T50015A  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 Engine Support: T50015A  . Avoid bumping the fan shroud with other components.

Vehicles with diesel engine and 1.4L gasoline engine 

-- 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 

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

Continuation for All 

-- Remove the bolt for the right flange shaft using the Socket and Extended Bit: T10107A  .

-- Insert two bolts in the flange and counterhold the flange shaft with the tire iron.

Replace the countersunk bolt after removing.

Vehicles with EGR cooler 

-- Remove the EGR cooler, if necessary. Refer to the appropriate Service Information .

Continuation for All 

The bevel box upper bolts -arrow a- and -arrow 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.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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.

-- 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 Spindle Cover in the manual transmission.