Volkswagen Golf Variant / Jetta. Manual - part 260

 

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Volkswagen Golf Variant / Jetta. Manual - part 260

 

 

transmission.

– Carefully push the bevel box off the manual transmission and

remove it.

9.3.2

Bevel Box, Installing

Install in reverse order of removal while. Note the following:
Install the bevel box with the flange shaft removed.
– Coat the splines on the manual transmission differential with

Grease For Clutch Disc Shaft Splines - G 000 100- .

– Slide on bevel box completely on manual transmission, while

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

differential.

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

up to stop against manual transmission.

Note

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

sion. Otherwise bevel box is canted and mounting eyelets can

break off.

– Install the upper bolts (-arrows-) that attach the bevel box to

the manual transmission and tighten them to 40 Nm + 90°.

– Install the lower bolts -arrows- that attach the bevel box to the

manual transmission and tighten them to 40 Nm + 90°.

9. Bevel Box, Removing and Installing    

215

bevel gear while observing the tightening sequence for the

bolts -A and B-. Refer to

⇒ “9.3.3 Tightening Specifications”, page 217

 .

– Carefully drive in the left flange shaft. While doing so turn the

flange shaft so that the bearing does not get damaged.

– Install flange shaft with a screw and tighten to tightening spec‐

ification -item 13- 

⇒ Item 13 (page 401)

 .

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

– Fill the bevel box with gear oil. Refer to

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

 .

– 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

 .

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

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

Note

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 .

216

view - Subframe .

– Assemble the exhaust system and then attach the exhaust

50 ; Noise Insulation .

9.3.3

Tightening Specifications

Bevel box to manual

transmission

♦ Replace the bolts.

⇒ Item 17 (page 235)

Allocation of the transmission support bolts to the engine and

bevel box

Item

Bolt

Quantity

A M10 x 21

2

B M10 x 45

2

– Hand-tighten all bolts.
– Tighten the bolts -B- to 40 Nm.
– Tighten the bolts -A- to 40 Nm.

9. Bevel Box, Removing and Installing    

217

Axle Oil in Bevel Box, Checking or

Adding

⇒ “10.1 Gear Oil in Bevel Box, Checking”, page 218
⇒ “10.2 Gear Oil in Bevel Box, Filling”, page 219

Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Used Oil Collection and Extraction Unit - SMN372500-
♦ Charging Device For Haldex Coupling 2 - VAS6291A-
♦ Charging Device For Haldex Coupling 2 - Adapter 3 -

VAS6291/3-

♦ It is necessary to use the Oil Filler - Adapter 6 - VAS6262/6-

on some oil containers.

Bevel Box is Attached to the Side of Manual Transmission and

has A Separate Self-Contained Oil System.
Bevel box gear oil. Refer to the Parts Catalog.
Check transmission fluid level inside the manual transmission.

Refer to 

⇒ “8 Transmission Fluid, Checking”, page 192

 .

10.1

Gear Oil in Bevel Box, Checking

Requirements
• Bevel box must be in the installation position.
– Remove the noise insulation. Refer to ⇒  Body Exterior; Rep.

Gr.  50 ; Noise Insulation .

– Remove the right drive axle heat shield from bevel box

-arrows-.

– Place the Used Oil Collection and Extraction Unit -

SMN372500- under the bevel box.

Note

Cover area below oil filler bolt -arrow- with a cloth.

– Remove the oil filler plug -arrow- in the bevel box.
The oil filler plug -arrow- must be replaced.
Oil level is correct if bevel box is filled with oil as far as bottom

edge of oil fill hole.
If oil comes in contact with bevel box, remove the bevel box care‐

fully.
– Add gear oil if necessary. Refer to

⇒ “10.2 Gear Oil in Bevel Box, Filling”, page 219

 .

– Install the new oil filler plug -arrow-.
– Tighten the bolt to the specification. Refer to

⇒ “10.2.1 Tightening Specification”, page 221

 .

218

 

 

 

 

 

 

 

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