Get OperationandHousing -> 9.3 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

Install the Transmission Mount

Allocation of bolts

Item

Bolt

Quantity

M10 x 21

M10 x 45

M10 x 62

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

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the right driveshaft heat shield from bevel box

-arrows-.

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

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

– Mark the position of the drive axle with the flexible disk with

respect to the bevel gear flange with paint.

– Remove the driveshaft from the bevel box -arrows-. Refer to

⇒ Rear Final Drive; Rep. Gr. 39 .

– Slide the front driveshaft pipe all the way back.

– Place a cloth on the subframe to prevent damaging the paint

on the driveshaft.

– Position the driveshaft on the subframe.

– 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 .

– 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.

212

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 exhaust system bracket from the subframe

-arrows-.

– Remove the pendulum support from the transmission, bolt

-1- and bolt -2-.

– Press the engine/transmission sub-assembly slightly toward

the front end and secure it in this position with a suitable wood

block -A-.

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

VAS6208- under the transmission.

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

– Install the new drain plug and tighten it to 15 Nm.

– 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.

9. Bevel Box, Removing and Installing

213

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

6-Speed Manual Transmission 02Q - Edition 05.2013

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

Note

To remove right flange shaft, use Puller - Flanged Shaft - T10037-

to avoid damaging the bearing on flange shaft.

– If necessary, place a spacer (for example, Press Piece - Bush‐

ing - VW434- ) between the transmission support and the Stub

Shaft counterhold 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 turbocharger support. Refer to ⇒ Rep. Gr. 21 .

– Remove the transmission support bolts -A and B- from the en‐

gine and the bevel box.

– Remove the transmission mount.

– Remove the upper bevel box bolts -arrows- on the manual

transmission.

214

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 lower bevel box bolts -arrows- on the manual

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

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– Fasten the bevel gear transmission mount to the engine and

bevel gear while observing the tightening sequence for the

bolts -A and B-. Refer to

⇒ “9.3.3 Tightening Specifications”, page 217 .

– 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 .

– 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 .

– 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‐

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

40 ; Subframe; Overview - Subframe .

216

Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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 .

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

50 ; Noise Insulation .

9.3.3

Tightening Specifications

Bevel box to manual

transmission

⇒ Item 17 (page 235)

♦ Replace the bolts.

Allocation of the transmission support bolts to the engine and

bevel box

Item

Bolt

Quantity

M10 x 21

M10 x 45

– 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

OperationandHousing -> 9.3 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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