Overview - Bevel Box Components

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

Fig 1: Bevel Box Components 0CN

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Seal
   • Replace after removing
   • Between the bevel box and manual transmission
   • Replacing. Refer to SEAL BETWEEN BEVEL BOX AND MANUAL TRANSMISSION, REPLACING ON BEVEL BOX .
2. Bevel Box
   • Removing. Refer to BEVEL BOX, REMOVING .
   • Installing. Refer to BEVEL BOX, INSTALLING .
   • Removing, Transmission Removed. Refer to Figure.
   • Installing, Transmission Removed. Refer to Figure.
3. Fluid Drain Plug
   • 15 Nm
   • Replace after removing
   • With permanent seal
4. Fluid Filler Plug
   • 15 Nm
   • Replace after removing
   • With permanent seal
5. Seal
   • Replace after removing
   • For the right flange shaft
   • Replacing. Refer to RIGHT SEAL, REPLACING, AWD .
6. Bleed Pipe
   • For bleeding the bevel box
   • Press it in all the way
7. Cap
   • For bleeding the bevel box
8. Right Flange Shaft
   • Removing and installing. Refer to RIGHT SEAL, REPLACING, AWD .
9. Seal
   • Replace after removing
   • To replace, remove the needle bearing (polygon bearing). Refer to NEEDLE BEARING (POLYGON BEARING) AND NEEDLE BEARING SEAL ON THE RIGHT FLANGE SHAFT, REPLACING .
10. 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. An acoustic test can only be performed while installed.
    • Check for damage on the bearing, for example, cracks on outer race and replace if necessary.
    • Replacing. Refer to NEEDLE BEARING (POLYGON BEARING) AND NEEDLE BEARING SEAL ON THE RIGHT FLANGE SHAFT, REPLACING .
11. Circlip
    • Replace after removing
    • For the needle bearing (polygon bearing)
    • Insert in the groove all around the stub shaft
12. 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
13. Output Flange
    • Replacing. Refer to OUTPUT FLANGE, REPLACING; OUTPUT FLANGE SHIM, REDETERMINING .
14. Shim
    • When replacing the output flange, redetermine the thickness. Refer to OUTPUT FLANGE, REPLACING; OUTPUT FLANGE SHIM, REDETERMINING .
15. Seal
    • Replace after removing
    • For the output flange
    • Replacing. Refer to BEVEL BOX OUTPUT FLANGE SEAL, REPLACING .
16. Inner Race/Tapered Roller Bearing
    • The component is not a replacement part
17. Bolt
    • 38 Nm
18. 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.
19. 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
20. Shim
    • The component is not a replacement part
    • Note the bevel box fastening holes; the shim only fits in one position
21. Cap
    • Drive in until stop using the Holding Fixture - Spacers: VW540/1B