Volkswagen Golf Variant / Jetta. Manual - part 259

 

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Volkswagen Golf Variant / Jetta. Manual - part 259

 

 

Item

Bolt

Quantity

1 M10 x 21

3

2 M10 x 45

2

3 M10 x 62

1

The following assembly sequence must be followed when instal‐

ling the transmission mount:
– Hand-tighten all bolts.
– Tighten the bolts -arrows 2 and 3- to 40 Nm.
– Tighten the bolts -arrows 1- to 40 Nm.

9.3

Bevel Box, Removing and Installing, Ve‐

hicles with a Turbo Diesel Engine with a

Particulate Filter, through Approximate‐

ly 11/2009

⇒ “9.3.1 Bevel Box, Removing”, page 211
⇒ “9.3.2 Bevel Box, Installing”, page 215
⇒ “9.3.3 Tightening Specifications”, page 217

Note

Transmission mount through approximately 10/2009; Bevel box,

Removing and installing. Refer to

⇒ “9.2 Bevel Box, Removing and Installing, Vehicles with a Turbo

Diesel Engine with a Particulate Filter, through approximately

10/2009”, page 201

 .

Identifying Feature
After 11/2009, a »Brace« -arrow 2- Is Installed Under the Vacuum

Diaphragm -arrow 1- At the top of the Transmission Support

(Gradual Introduction).
The Transmission Mount Is Connected to the Engine and Bevel

Gear with the Bolts -A and B-.

Special tools and workshop equipment required
♦ Puller - Flanged Shaft - T10037-
♦ Socket And Extended Bit - T10107A-
♦ Cover Cap - T10460-
♦ Shop Crane - Drip Tray - VAS6208-

9.3.1

Bevel Box, Removing

– Remove the noise insulation under the engine/transmission

assembly. Refer to ⇒  Body Exterior; Rep. Gr.  50 ; Noise In‐

sulation .

9. Bevel Box, Removing and Installing    

211

-arrows-.

– Remove the right drive axle. Refer to ⇒  Suspension, Wheels,

– Mark the position of the drive axle with the flexible disk with

respect to the bevel gear flange with paint.

– Remove the driveshaft from the bevel box -arrows-. Refer to

⇒  Rear Final Drive; Rep. Gr.  39 .

– Slide the front driveshaft pipe all the way back.
– Place a cloth on the subframe to prevent damaging the paint

on the driveshaft.

– Position the driveshaft on the subframe.
– Remove the engine cover.

– Remove the upper particulate filter -A- from the engine

-arrow 1- and from under the turbocharger -arrow 2-. Refer to

– Loosen the nuts -1- and remove the nuts -2- to remove the

particulate filter bracket from the engine.

– Then tie the particulate filter to the plenum chamber bulkhead.

212

-arrows-.

– Remove the pendulum support from the transmission, bolt

-1- and bolt -2-.

– Press the engine/transmission sub-assembly slightly toward

the front end and secure it in this position with a suitable wood

block -A-.

– Place the Drip Tray for example Shop Crane - Drip Tray -

VAS6208- under the transmission.

– Drain the fluid from the bevel box -A-.
– Install the new drain plug and tighten it to 15 Nm.
– Remove the right flange shaft bolt -arrow- with the Socket And

Extended Bit - T10107A- and install two bolts in the flange and

counterhold the flange shaft with the pry bar.

9. Bevel Box, Removing and Installing    

213

Note

To remove right flange shaft, use Puller - Flanged Shaft - T10037-

to avoid damaging the bearing on flange shaft.

– If necessary, place a spacer (for example, Press Piece - Bush‐

ing - VW434- ) between the transmission support and the Stub

Shaft counterhold Tool - Knurled Nut - T10371/1- .

– Align the Puller - Flanged Shaft - T10037- parallel to the flange

using the Spindle -A-.

– Pull out the right flange shaft.

– Seal the bevel box with a Cover Cap - T10460- .

gine and the bevel box.

– Remove the transmission mount.

– Remove the upper bevel box bolts -arrows- on the manual

transmission.

214

 

 

 

 

 

 

 

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