Get OperationandHousing -> 9.2 Bevel Box... Vehicles with a Turbo Diesel Engine with a 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

9.1.3

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

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

6-Speed Manual Transmission 02Q - Edition 05.2013

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 .

9.2.1

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

– 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-).

202

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 cable bracket from the transmission -arrows-, tie

up to the side.

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

Continuation for All

The right driveshaft must be removed later in the procedure.

– With the vehicle still standing on its wheels, loosen the right

front collar bolt -arrow- a maximum 90°, otherwise the wheel

bearing will get damaged. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– 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.

9. Bevel Box, Removing and Installing

203

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.

204

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 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 .

– Remove the support -A- (if equipped). Refer to ⇒ Rep. Gr.

26 ; Exhaust System .

– Remove the right drive axle heat shield from bevel box

-arrows-.

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

Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

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

VAS6208- under the transmission.

9. Bevel Box, Removing and Installing

205

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– Drain the fluid from the bevel box -A-.

– 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.

– Finally, insert and tighten new bolts -A-.

Bolt M10 X 1 = 15 Nm

Bolt M20 X 1.5 = 60 Nm

– Attach the Puller - Flanged Shaft - T10037- to the flange shaft.

Note

To remove right flange shaft, use Seal Installer - Crankshaft -

T10037- to avoid damaging the bearing on flange shaft.

– Place a spacer (for example, Press Piece - Bushing - VW434- )

between the transmission support and the Stub Shaft coun‐

terhold 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- .

– Remove the engine cover.

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

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

⇒ Rep. Gr. 26 ; Exhaust System .

206

Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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.

– Remove the turbocharger support. Refer to ⇒ Rep. Gr. 21 .

– Remove the EGR cooler (do not remove the coolant hoses) ⇒

Rep. Gr. 26 ; EGR System .

– Remove the transmission mount bolts on the engine and bevel

gear -arrows 1-, -arrows 2- and -arrow 3-.

– Remove the transmission mount.

– 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

207

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– If replacing the bevel box, check whether the heat shield -A-

must be removed.

9.2.2

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.

– 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 gear transmission mount to the engine and

bevel gear. Follow the tightening sequence when installing the

bolts -arrows 1, 2, and 3-. Refer to

⇒ “9.2.3 Tightening Specifications”, page 210 .

– Install the turbocharger support. Refer to ⇒ Rep. Gr. 21 .

– Attach the particulate filter with the particulate filter bracket to

the engine. Refer to ⇒ Rep. Gr. 26 .

– Install the EGR cooler (do not open the coolant system) ⇒

Rep. Gr. 26 ; EGR System .

208

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 .

– 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,

Steering; Rep. Gr. 40 ; Drive Axles, Removing 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 .

– 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

209

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 .

9.2.3

Tightening Specifications

Bevel box to manual transmission

♦ Replace the bolts.

⇒ Item 17

(page 235)

210

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 Transmission Mount

Allocation of bolts

Item

Bolt

Quantity

1

2

3

M10 x 21

M10 x 45

M10 x 62

3

2

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

OperationandHousing -> 9.2 Bevel Box... Vehicles with a Turbo Diesel Engine with a Particulate Filter... for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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