Volkswagen Golf Variant / Jetta. Manual - part 255

 

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Volkswagen Golf Variant / Jetta. Manual - part 255

 

 

bevel gear flange.

– Remove the driveshaft and flexible disk from the bevel gear

flange shaft -arrows-.

– Disconnect the connector -1- from the Oil Level Thermal Sen‐

sor - G266- .

– Remove the pendulum support from the transmission.

Note

After loosening the pendulum support bolts, the engine/transmis‐

sion assembly swings forward slightly (toward the front end).

Ensure that the sealing ring -arrow- in the flange of the driveshaft

is not damaged during removal and installation.

– Press the engine/transmission assembly slightly forward (to‐

ward the front end) and pull the driveshaft off of the bevel gear.

– Lift the driveshaft and secure it.
– Remove the left and right coupling rods from the stabilizer bar.

9. Bevel Box, Removing and Installing    

195

sion, Wheels, Steering; Rep. Gr.  40 ; Subframe; Subframe,

Securing .

– Remove subframe with pendulum support, stabilizer bar,

brackets, steering gear and control arms. Refer to ⇒  Suspen‐

sion, Wheels, Steering; Rep. Gr.  40 ; Subframe; Overview -

Subframe .

– Remove the right drive axle heat shield from bevel box

-arrows-.

– Remove right drive axle from transmission flange shaft.
– Secure the drive axle. Do not damage the protective coating

when doing this.

– Remove the turbocharger oil return line -A- from the engine.

– Remove the transmission mount bolts at the engine and bevel

gear -arrows 1 and arrows 2-.

– Remove the transmission mount.

196

– Remove the right flange shaft bolt with a Socket for example

Socket and Extended Bit - T10107A- -arrow 1-.

Note

Right flanged shaft remains in bevel box.

– Remove the lower bevel gear mounting bolts -arrows- at the

manual transmission.

– Remove upper bevel box mounting bolt at manual transmis‐

sion:

A heat shield -arrow A- is installed on the upper side of the bevel

box on some vehicles.
The bolt -arrow B- is accessible from under the heat shield.
The bolt -arrow C- is accessible from above the heat shield.
– Carefully press bevel box off manual transmission while pro‐

tecting it against falling through.

– Remove bevel box.

9. Bevel Box, Removing and Installing    

197

is being replaced.

9.1.2

Bevel Box, Installing

Install in reverse order of removal while. Note the following:
– With the manual transmission installed, lubricate differential

splines with Grease for Clutch Disc Shaft Splines - G 000 100- .

– If the bevel box is being replaced, then install heat shield -A-.
– Tighten the mounting bolts -arrows- to 5 Nm.
– Slide on bevel box completely on manual transmission, while

doing this, join splines of input shaft/bevel box centrally with

differential.

– Bring the right drive axle splines and the differential bevel gear

into alignment. Rotate the flange shaft if necessary.

– With proper tooth position and central guiding, bevel box slips

up to stop against manual transmission.

A heat shield -arrow A- is installed on the upper side of the bevel

box on some transmissions.
– Upper bevel box mounting bolts at manual transmission are

accessible as follows:

The bolt -arrow B- is accessible from under the heat shield.
The bolt -arrow C- is accessible from above the heat shield.

Note

Do not pull bevel box with mounting bolts against the transmis‐

sion. Otherwise bevel box is canted and mounting eyelets can

break off.

– Attach the bevel box transmission support to the engine. Fol‐

low the tightening sequence when installing the bolts

-arrows 1 and arrows 2-. Refer to

⇒ “9.1.3 Tightening Specifications”, page 201

 .

– Attach the turbocharger oil return line -A- to the engine. Refer

198

 

 

 

 

 

 

 

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