Volkswagen Golf Variant / Jetta. Manual - part 301

 

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Volkswagen Golf Variant / Jetta. Manual - part 301

 

 

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

20 - Inner Race / Tapered Roller Bearing

❑ Component is not a replacement part

21 - Bolt

❑ 25 Nm

22 - Pinion Housing

❑ With shaft bevel gear and outer race/tapered roller bearing
❑ Components are not replacement parts
❑ Carefully pry out from side to side
❑ Note the fastening holes; the pinion housing only fits in one position

23 - O-Ring

❑ To replace, remove the bolts -item 21- 

⇒ Item 21 (page 379)

 and carefully pry the drive pinion housing

out at the tabs protruding all the way around.

❑ Do not remove the hex nut -item 15- 

⇒ Item 15 (page 378)

 and output flange -item 16-

⇒ Item 16 (page 378)

 .

24 - Shim

❑ Component is not a replacement part
❑ Note the bevel box fastening holes; the shim only fits in one position

25 - Cap

❑ Drive in until stop using the Holding Fixture - Spacers - VW540/1B-

3.1

Bevel Box, Removing and Installing

(Manual Transmission Removed)

Special tools and workshop equipment required
♦ Socket And Extended Bit - T10107A-
♦ Shop Crane - Drip Tray - VAS6208-

Note

Secure the transmission on the assembly stand. Refer to

⇒ “7 Transmission, Securing in Engine/Transmission Holder”,

page 191

 .

Remove the Bevel Box from the Manual Transmission as Follows:
– Place a Workshop Crane Drip Tray for example Shop Crane -

Drip Tray - VAS6208- underneath.

– Remove right flange shaft countersunk screw with Socket And

Extended Bit - T10107- or Socket And Extended Bit -

T10107A- .

– Remove the four bolts -arrows- (only three bolts are shown in

the illustration) that attach the bevel box to the manual trans‐

mission.

– Carefully press bevel box off manual transmission while pro‐

tecting it against falling through.

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

379

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

differential.

– Line up the splines on the right flange shaft with the differential

bevel gear. Turn the flange shaft if necessary.

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

up to stop against manual transmission.

Caution

The bevel box housing may become damaged.

♦ Do not pull bevel box with mounting bolts against manual

transmission, otherwise bevel box is canted and mounting

eyelets can break off.

– Remove the four bolts -arrows- (only three bolts are shown in

the illustration) that attach the bevel box to the manual trans‐

mission -item 17- 

⇒ Item 17 (page 235)

 for the tightening

specification.

– Tighten the right flange shaft countersunk bolt with Socket And

Extended Bit - T10107- or Socket And Extended Bit -

T10107A- -item 13- 

⇒ Item 13 (page 401)

 for the tightening

specification.

3.2

Gasket on Bevel Box between Manual

Transmission and Bevel Box, Replacing

Special tools and workshop equipment required
♦ Puller - Crankshaft/Power Steering Seal - T20143-
♦ Seal Installer - Bevel Box - T10298-
– Remove the bevel box. Refer to

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

 .

– Remove the gasket using the Puller - Crankshaft/Power Steer‐

ing Seal - 1 - T20143/1- or Puller - Crankshaft/Power Steering

Seal - 2 - T20143/2- .

380

sion fluid.

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

Sealing Grease - G 052 128 A1- .

– Drive the gasket all the way in using the Seal Installer - Bevel

Box - T10298- . Do not tilt it while doing so.

– 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

 .

3.3

Bevel Box Output Flange Seal, Replac‐

ing (Bevel Box Removed)

Special tools and workshop equipment required
♦ Holding Fixture - VW313-
♦ Press Piece - 42mm - VW516-
♦ Press Piece - Multiple Use - 40-105-
♦ Seal Installer - Flange Shaft - T10049-
♦ Gearbox Support - T10108-
♦ Counter Holder - T10108/1-
♦ Puller - Taper Roller Bearing - VAG1582- with a short sleeve
♦ Seal is located in the pinion housing. Refer to

⇒ Fig. ““Output Flange Seal in Pinion Housing, Removing and

Installing”“ , page 384

 . Puller - Taper Roller Bearing - Adapter

6 - VAG1582/6- or Puller - Taper Roller Bearing - Adapter 6A

- VAG1582/6A-

♦ -1- Puller - Kukko 2-Arm - 70-180mm - 20/10-
♦ Seal is located on the output flange. Refer to

⇒ Fig. ““Output Flange Seal -arrow- Removing and Instal‐

ling:”“ , page 385

 . Puller - Taper Roller Bearing - Adapter 13

- VAG1582/13-

♦ Continuation for All
♦ Torque Wrench 1601 - VAG1601-
♦ Three-Arm Puller - 45–2-
♦ The seal is located on the output flange

⇒ Fig. ““Output Flange Seal -arrow- Removing and Instal‐

ling:”“ , page 385

♦ Press Piece - Multiple Use - VW412-

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

381

⇒ Fig. ““Output Flange Seal in Pinion Housing, Removing and

Installing”“ , page 384

♦ Slide Hammer Set - VW771-
♦ Only for seal in pinion housing. Refer to

⇒ Fig. ““Output Flange Seal in Pinion Housing, Removing and

Installing”“ , page 384

♦ Slide Hammer Set - Hook - VW771/37-
♦ Two M 10 x 30 bolts
♦ Four M 12 x 10 nuts

Note

Bevel box output flange seal can only be replaced with bevel

box removed.

Inner race/tapered roller bearing is located in the output flange

bevel box.

This is removed later in the procedure.

Do not replace the tapered roller bearing for the output flange

bevel box and the shim!

– Remove the bevel box. Refer to

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

 .

– Mount the bevel box on the hole marked with the number -4-

-arrow- in the Gearbox Support - T10108- .

A - Insert the M 12 x 10 nut (quantity: 4) between bevel box and

Transmission Holder .
– Then align bevel box to the remaining three holes and secure.
– Place a drip tray underneath.
– Drain the gear oil out of the bevel box.
– Install two M 10 x 30 bolts -arrows- to stop the output flange

for the bevel box with the Gearbox Support - Stop Plate -

T10108/1- .

382

 

 

 

 

 

 

 

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