Get OperationandHousing -> 9.1 Bevel Box, Vehicles with TDI Engine without Particulate Filter... Guide for Volkswagen Golf 4 Door Fifth Generation (2003-2008)

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

9

Bevel Box, Removing and Installing

⇒ “9.1 Bevel Box, Vehicles with TDI Engine without Particulate

Filter, Removing and Installing”, page 193

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

Diesel Engine with a Particulate Filter, through approximately

10/2009”, page 201

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

Diesel Engine with a Particulate Filter, through Approximately

11/2009”, page 211

9.1

Bevel Box, Vehicles with TDI Engine

without Particulate Filter, Removing and

Installing

⇒ “9.1.1 Bevel Box, Removing”, page 193

⇒ “9.1.2 Bevel Box, Installing”, page 198

⇒ “9.1.3 Tightening Specifications”, page 201

Special tools and workshop equipment required

♦ Socket And Extended Bit - T10107A-

♦ Torque Wrench 1331 5-50Nm - VAG1331-

♦ Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

9.1.1

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

9. Bevel Box, Removing and Installing

193

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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-).

– Remove the cable bracket from the transmission -arrows-, tie

up to the side.

– Remove the breather tube from the bevel gear -arrow-.

Continuation for All

– Raise the vehicle.

– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.

Gr. 50 ; Noise Insulation .

– Disconnect the exhaust system at the clamping sleeve and

remove the exhaust system bracket from the subframe

-arrows-.

– Tie up the front exhaust pipe.

194

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Mark the position of the driveshaft with the flexible disk to the

bevel gear flange.

– Remove the driveshaft and flexible disk from the bevel gear

flange shaft -arrows-.

– Disconnect the connector -1- from the Oil Level Thermal Sen‐

sor - G266- .

– Remove the pendulum support from the transmission.

Note

After loosening the pendulum support bolts, the engine/transmis‐

sion assembly swings forward slightly (toward the front end).

Ensure that the sealing ring -arrow- in the flange of the driveshaft

is not damaged during removal and installation.

– Press the engine/transmission assembly slightly forward (to‐

ward the front end) and pull the driveshaft off of the bevel gear.

– Lift the driveshaft and secure it.

– Remove the left and right coupling rods from the stabilizer bar.

9. Bevel Box, Removing and Installing

195

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the nuts -arrows- for the ball joint on the control arm.

– Secure the subframe before removing. Refer to ⇒ Suspen‐

sion, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe,

Securing .

– Remove subframe with pendulum support, stabilizer bar,

brackets, steering gear and control arms. Refer to ⇒ Suspen‐

sion, Wheels, Steering; Rep. Gr. 40 ; Subframe; Overview -

Subframe .

– Remove the right drive axle heat shield from bevel box

-arrows-.

– Remove right drive axle from transmission flange shaft.

– Secure the drive axle. Do not damage the protective coating

when doing this.

– Remove the turbocharger oil return line -A- from the engine.

Refer to ⇒ Rep. Gr. 21 .

– Remove the transmission mount bolts at the engine and bevel

gear -arrows 1 and arrows 2-.

– Remove the transmission mount.

196

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the support -A-, if equipped. Refer to ⇒ Rep. Gr. 26 .

– Remove the right flange shaft bolt with a Socket for example

Socket and Extended Bit - T10107A- -arrow 1-.

Note

Right flanged shaft remains in bevel box.

– Remove the lower bevel gear mounting bolts -arrows- at the

manual transmission.

– Remove upper bevel box mounting bolt at manual transmis‐

sion:

A heat shield -arrow A- is installed on the upper side of the bevel

box on some vehicles.

The bolt -arrow B- is accessible from under the heat shield.

The bolt -arrow C- is accessible from above the heat shield.

– Carefully press bevel box off manual transmission while pro‐

tecting it against falling through.

– Remove bevel box.

9. Bevel Box, Removing and Installing

197

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– The heat shield -A- must be removed -arrows- if the bevel box

is being replaced.

9.1.2

Bevel Box, Installing

Install in reverse order of removal while. Note the following:

– With the manual transmission installed, lubricate differential

splines with Grease for Clutch Disc Shaft Splines - G 000 100- .

– If the bevel box is being replaced, then install heat shield -A-.

– Tighten the mounting bolts -arrows- to 5 Nm.

– Slide on bevel box completely on manual transmission, while

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

differential.

– Bring the right drive axle splines and the differential bevel gear

into alignment. Rotate the flange shaft if necessary.

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

up to stop against manual transmission.

A heat shield -arrow A- is installed on the upper side of the bevel

box on some transmissions.

– Upper bevel box mounting bolts at manual transmission are

accessible as follows:

The bolt -arrow B- is accessible from under the heat shield.

The bolt -arrow C- is accessible from above the heat shield.

Note

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

sion. Otherwise bevel box is canted and mounting eyelets can

break off.

– Attach the bevel box transmission support to the engine. Fol‐

low the tightening sequence when installing the bolts

-arrows 1 and arrows 2-. Refer to

⇒ “9.1.3 Tightening Specifications”, page 201 .

– Attach the turbocharger oil return line -A- to the engine. Refer

to ⇒ Rep. Gr. 21 .

198

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the support -A-, if equipped. Refer to ⇒ Rep. Gr. 26 .

– 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

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

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‐

ifications. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr.

40 ; Subframe; Overview - Subframe .

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

Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Over‐

view - Subframe .

– Assemble the exhaust system and then attach the exhaust

system bracket it to the subframe. Refer to ⇒ Rep. Gr. 26 .

– 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 .

– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.

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 .

– Install complete air filter housing. Refer to ⇒ Rep. Gr. 23 ;

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

Equipment; Rep. Gr. 94 ; Headlamps; Headlamp, Adjusting .

200

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

9.1.3

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

OperationandHousing -> 9.1 Bevel Box, Vehicles with TDI Engine without Particulate Filter... for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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