Volkswagen Golf Variant / Jetta. Manual - part 256

 

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Volkswagen Golf Variant / Jetta. Manual - part 256

 

 

– Mount the right drive axle to the transmission. Refer to ⇒  Sus‐

pension, Wheels, Steering; Rep. Gr.  40 ; Drive Axles, Re‐

moving and Installing .

– Attach the right drive axle heat shield to the bevel box

-arrows- and tighten it to the tightening specification. Refer to

⇒ “9.1.3 Tightening Specifications”, page 201

 .

– Install subframe with pendulum support, stabilizer bar, brack‐

ets, steering gear and control arms. Refer to ⇒  Suspension,

Wheels, Steering; Rep. Gr.  40 ; Subframe; Overview - Sub‐

frame .

– Attach the driveshaft with the flexible disc to the bevel box

flange -arrows-. Refer to ⇒  Rear Final Drive; Rep. Gr.  39 .

9. Bevel Box, Removing and Installing    

199

The holes for the pendulum support in transmissions from

05/28/2007 have threaded inserts (for example “Heli Coil”).

Characteristic: there is a collar on the first thread -arrow-.

Pay attention to the corresponding bolts and tightening spec‐

40 ; Subframe; Overview - Subframe .

– Attach the pendulum support to the transmission. Refer to ⇒ 

view - Subframe .

– Assemble the exhaust system and then attach the exhaust

– Check the gear oil in the bevel box. Refer to

⇒ “10 Axle Oil in Bevel Box, Checking or Adding”, page 218

 .

– Check transmission fluid level inside the manual transmission.

Refer to 

⇒ “8 Transmission Fluid, Checking”, page 192

 .

50 ; Noise Insulation .

– If equipped, install the breather tube -arrow- in the bevel gear

and tighten to 10 Nm.

If shift mechanism was removed from transmission:

– Attach the cable mounting bracket to the transmission and

tighten the bolts and nuts -arrows- to the tightening specifica‐

tion -item 6- 

⇒ Item 6 (page 86)

 and -item 10-

⇒ Item 10 (page 86)

 .

– Install and adjust shift mechanism. Refer to

⇒ “1.9 Selector Mechanism, Removing and Installing”,

page 92

 .

Diesel Direct Injection System; Air Filter Housing, Removing

and Installing .

– Check the headlamp adjustment if the vehicle has a Left Front

Level Control System Sensor - G78- . Refer to ⇒  Electrical

200

Tightening Specifications

Installing the Transmission Support on TDI Vehicles
The following assembly sequence must be followed when instal‐

ling the transmission mount:
– Install the bolts -arrows 1- hand-tight.
– Tighten the bolts -arrows 2- to 40 Nm.
– Tighten the bolts -arrows 1- to 40 Nm.

Bevel box to manual transmission

♦ Replace the bolts.

-item 17-

⇒ Item 17

(page 235)

Right heat shield/drive axle to bevel gear

20 Nm

9.2

Bevel Box, Removing and Installing, Ve‐

hicles with a Turbo Diesel Engine with a

Particulate Filter, through approximately

10/2009

⇒ “9.2.1 Bevel Box, Removing”, page 202
⇒ “9.2.2 Bevel Box, Installing”, page 208
⇒ “9.2.3 Tightening Specifications”, page 210

Note

Transmission mount from approximately 11/2009: Bevel Box, Re‐

moving and installing. Refer to

⇒ “9.3 Bevel Box, Removing and Installing, Vehicles with a Turbo

Diesel Engine with a Particulate Filter, through Approximately

11/2009”, page 211

 .

Identification: The Transmission Support is Secured with the Bolts

-arrows 1 … 3- to the Engine and the Bevel Box through Approx‐

imately 10/2009.

Special tools and workshop equipment required
♦ Socket And Extended Bit - T10107A-

♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Shop Crane - Drip Tray - VAS6208-
♦ Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

9. Bevel Box, Removing and Installing    

201

Transmission mount from approximately 11/2009: Bevel Box, Re‐

moving and installing. Refer to

⇒ “9.3 Bevel Box, Removing and Installing, Vehicles with a Turbo

Diesel Engine with a Particulate Filter, through Approximately

11/2009”, page 211

 .

9.2.1

Bevel Box, Removing

Check whether a breather tube -arrow- is mounted on the bevel

gear.
– Remove the entire air filter housing if necessary. Refer to ⇒ 

Rep. Gr.  23 ; Diesel Direct Injection System; Air Filter Hous‐

ing, Removing and Installing .

To remove breather tube, shift mechanism must be removed from

transmission:

– Remove the shift cable lock washer -3- from the transmission

shift lever -1- and remove the cable from the pin -arrow-.

Metal Relay Lever
– Remove the selector cable lock washer -4- from the relay lever

-2- and remove the cable from the pin -arrow-.

Plastic Relay Lever

– Remove the cable retainer from the selector cable.
• To avoid damage to the selector cable, the cable retainer must

be disconnected from the selector lever before removal.

– Pull the securing mechanism all the way forward in direction

of -arrow 1- and then unlock to the left in direction of

-arrow 2-.

– Press the relay lever forward (in the direction of -arrow 3-).

202

 

 

 

 

 

 

 

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