Bevel Box, Removing, Vehicles With 3.6L, 206 Kw Engine

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Special tools and workshop equipment required 

• Slide Hammer Set:VW771 
• Hex Ball Socket:3247 
• Holding Fixture - Spacers:VW540/1B 
• Puller - Bevel Gear:T10472 
• Counterhold - Multiple Use:T10172A 
  Fig 1: Counterhold - Kit - Multiple Use T10172

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-- Lift the vehicle, all four mounts from lifting platform at the same height.

-- Turn the steering to the center position.

-- Move the selector lever to >>P<<.

-- Press the brakes and loosen the bolt on the right drive axle -arrow- (second technician). Refer to DRIVE AXLE, REMOVING AND INSTALLING .

Fig 2: Identifying Left Front Drive Axle Bolt

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-- Move the selector lever into >>N<<.

-- Remove the engine cover.

-- Remove the noise insulation below the engine/transmission. Refer to OVERVIEW - NOISE INSULATION .

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

-- If equipped, disconnect the connector -1- from the sensor for the Oil Level Thermal Sensor -G266-.

Fig 3: Disconnecting Connector From Oil Level Thermal Sensor G266

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

Fig 4: AWD:

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-- Remove the exhaust system front section. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING - 4 CYL or CATALYTIC CONVERTER, REMOVING AND INSTALLING - 6 CYL .

-- Remove the bolts -1 and 2- and bevel box transmission support -3-.

Fig 5: Transmission Support To Engine And Bevel Box (Vehicles with 3.6L - 206 kW Engine)

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-- If equipped, remove the driveshaft heat shield.

Fig 6: Identifying Heat Shield

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

Fig 7: Mark Position Of Driveshaft

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

Fig 8: Driveshaft Flexible Disc

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-- Counterhold the rear final drive to loosen and tighten the driveshaft.

Fig 9: Counterholding Rear Final Drive To Loosen And Tighten Driveshaft

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-- Remove the pendulum support bolts -1- from the transmission.

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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.

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

Fig 10: Identifying Driveshaft Flange Shaft Seal

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-- Place the left driveshaft on the steering gear shield. Place a cloth between the driveshaft and shield.

-- Remove the top of the bevel box from the transmission -arrows-.

Fig 11: Identifying Bevel Box To Transmission Top Bolts

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-- Only loosen the lower bolts for the bevel box on the transmission and loosen to the dimension -a-.

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Dimension -a- = 15 mm.

This prevents the bevel box from immediately falling when loosening with the Slide Hammer Set:VW771  .

-- Install the Puller - Bevel Gear:T10472  on the bevel box.

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-- Prepare the Slide Hammer Set:VW771  with a washer -a- and two sleeves from the Holding Fixture - Spacers:VW540/1B  as shown.

Fig 12: Complete The Slide Hammer Set VW771 Using The Holding Fixture - Spacers VW540/1B.

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-- Attach the Slide Hammer Set:VW771  to the Puller - Bevel Gear:T10472  and detach the bevel box from the transmission.

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-- Remove the Slide Hammer Set:VW771  and Puller - Bevel Gear:T10472  from the bevel box.

-- Remove the lower bolts -arrows- and the bevel box.

Fig 13: Identifying Bevel Box To Transmission Bottom Bolts

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