Volkswagen Golf Variant / Jetta. Manual - part 300

 

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Volkswagen Golf Variant / Jetta. Manual - part 300

 

 

– Fill the space between the sealing/dust lip -arrow- halfway with

Sealing Grease - G 052 128 A1- .

– 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,

– Remove the right drive axle heat shield -arrows-. Refer to ⇒ 

Suspension, Wheels, Steering; Rep. Gr.  40 ; Drive Axles,

Overview and Servicing; Drive Axle Heat Shield .

– 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 .

– Install the right front wheel. Refer to ⇒  Suspension, Wheels,

cations .

2.3

Bevel Box Seal, Replacing, with Manual

Transmission Installed

Note

The seal, located between the manual transmission and the bevel

box, seals the manual transmission.

Special tools and workshop equipment required
♦ Puller - Crankshaft/Power Steering Seal - 2 - T20143/2-
♦ Shop Crane - Drip Tray - VAS6208-
♦ Seal Installer - Bevel Box - T10243-
– Remove the bevel box. Refer to

⇒ “9 Bevel Box, Removing and Installing”, page 193

 .

2. Flange Shaft Seals and Bevel Box, Replacing for AWD Vehicles (Manual Transmission already Installed)    

375

VAS6208- under the transmission.

– Pry out the bevel box seal using the Puller - Crankshaft/Power

Steering Seal - 2 - T20143/2- or Puller - Seal Lever - VW681- .

– Coat the outer circumference of the new seal with transmis‐

sion fluid.

– Fill the space between the sealing/dust lip -arrow- halfway with

Sealing Grease - G 052 128 A1- .

– Install the seal all the way without tilting it.
– Install the bevel box. Refer to

⇒ “9 Bevel Box, Removing and Installing”, page 193

 .

– 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

 .

376

Overview - Seals, Flange Shaft Bear‐

ing and Output Flange Bearing inside

the Bevel Box

⇒ “3.1 Bevel Box, Removing and Installing (Manual Transmission

Removed)”, page 379
⇒ “3.2 Gasket on Bevel Box between Manual Transmission and

Bevel Box, Replacing”, page 380
⇒ “3.3 Bevel Box Output Flange Seal, Replacing (Bevel Box Re‐

moved)”, page 381
⇒ “3.4 Output Flange, Replacing and Selecting New Shim for

Output Flange, Bevel Box Removed”, page 387
⇒ “3.5 Needle Bearing (polygon bearing) on Right Flange Shaft

and Seal on Right Flange Shaft, Replacing”, page 387

1 - Seal

❑ Between bevel box and

manual transmission

❑ Replace with bevel box

removed. Refer to

⇒ “3.2 Gasket on Bevel

Box between Manual

Transmission and Bevel

Box, Replacing”,

page 380

2 - Bevel Box

❑ Removing and installing

with transmission instal‐

led. Refer to

⇒ “9 Bevel Box, Remov‐

ing and Installing”, page

193

 .

❑ Removing and installing

with transmission re‐

moved. Refer to

⇒ “3.1 Bevel Box, Re‐

moving and Installing

(Manual Transmission

Removed)”, page 379

 .

3 - Oil Drain Plug

❑ 15 Nm
❑ Replace after removing
❑ With permanent seal

Note

A fluid drain plug with M20 x 1.5

thread may be installed for some

bevel boxes.

The tightening specification for

this plug is 60 Nm.

4 - Oil Filler Plug

❑ 15 Nm
❑ Replace after removing
❑ With permanent seal

3. Overview - Seals, Flange Shaft Bearing and Output Flange Bearing inside the Bevel Box    

377

❑ For the right flange shaft
❑ Replace with manual transmission installed with bevel box. Refer to

⇒ “2.2 Right Flange Shaft Seal, Replacing”, page 373

 .

6 - Bleed Pipe

❑ For bleeding the bevel box
❑ Press it in until it stops

7 - Cap

❑ For bleeding the bevel box

8 - Vent Pipe

❑ 10 Nm
❑ Bevel box venting approximately through 12/2005
❑ Allocate the parts according to the Parts Catalog

9 - Bolt

❑ 5 Nm

10 - Heat Shield

❑ Not equipped for all bevel boxes
❑ The contour may be different from the illustration
❑ Allocate the parts according to the Parts Catalog

11 - Right Flange Shaft

❑ Removing and installing. Refer to 

⇒ “2.2 Right Flange Shaft Seal, Replacing”, page 373

 .

12 - Seal

❑ remove to replace needle bearing (polygon bearing -item 13- 

⇒ Item 13 (page 378)

 )

13 - Needle Bearing (Polygon Bearing)

❑ Replacing. Refer to

⇒ “3.5 Needle Bearing (polygon bearing) on Right Flange Shaft and Seal on Right Flange Shaft, Re‐

placing”, page 387

 .

14 - Circlip

❑ Replace after removing
❑ For the needle bearing (polygon bearing)
❑ Insert into the surrounding right flange shaft groove

15 - Hex Nut

❑ 480 Nm
❑ Removing. Refer to 

⇒ Fig. ““Unscrew Hex Nut for Output Flange.”“ , page 383

 .

❑ Install with Locking Compound - D 000 600- .
❑ Installing. Refer to

⇒ Fig. ““Coat Threads of the New Hex Head Nut with Locking Compound -D 000 600- .”“ , page 387

 .

16 - Output Flange

❑ Removing and installing with bevel box removed. Refer to

⇒ “3.3 Bevel Box Output Flange Seal, Replacing (Bevel Box Removed)”, page 381

17 - Cap

❑ Lock with the output flange

18 - Shim

❑ Determining the thickness when replacing the output flange. Refer to

⇒ “3.4 Output Flange, Replacing and Selecting New Shim for Output Flange, Bevel Box Removed”, page

387

19 - Seal

❑ For output flange

378

 

 

 

 

 

 

 

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