2003-2008 Volkswagen Golf 4 Door OperationandHousing -> 9 Bevel Box, Removing and Installing User Manual
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OperationandHousing -> 9 Bevel Box, Removing and Installing for Your 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  
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  
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  
A
B
Bolt  
Quantity  
M10 x 21  
M10 x 45  
2
2
– 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  

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