Get FinalDriveandDifferential -> 3 Overview - Seals, Flange Shaft Bearing and Output Flange Bearing inside the Bevel Box Guide for Volkswagen Jetta 4 Door Fourth Generation (1999-2005)

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

6-Speed Manual Transmission 02Q - Edition 05.2013

3

Overview - Seals, Flange Shaft Bear‐

ing and Output Flange Bearing inside

the Bevel Box

⇒ “3.1 Bevel Box, Removing and Installing (Manual Transmission

Removed)”, page 379

⇒ “3.2 Gasket on Bevel Box between Manual Transmission and

Bevel Box, Replacing”, page 380

⇒ “3.3 Bevel Box Output Flange Seal, Replacing (Bevel Box Re‐

moved)”, page 381

⇒ “3.4 Output Flange, Replacing and Selecting New Shim for

Output Flange, Bevel Box Removed”, page 387

⇒ “3.5 Needle Bearing (polygon bearing) on Right Flange Shaft

and Seal on Right Flange Shaft, Replacing”, page 387

1 - Seal

❑ Between bevel box and

manual transmission

❑ Replace with bevel box

removed. Refer to

⇒ “3.2 Gasket on Bevel

Box between Manual

Transmission and Bevel

Box, Replacing”,

page 380

2 - Bevel Box

❑ Removing and installing

with transmission instal‐

led. Refer to

⇒ “9 Bevel Box, Remov‐

ing and Installing”, page

193 .

❑ Removing and installing

with transmission re‐

moved. Refer to

⇒ “3.1 Bevel Box, Re‐

moving and Installing

(Manual Transmission

Removed)”, page 379 .

3 - Oil Drain Plug

❑ 15 Nm

❑ Replace after removing

❑ With permanent seal

Note

♦ A fluid drain plug with M20 x 1.5

thread may be installed for some

bevel boxes.

♦ The tightening specification for

this plug is 60 Nm.

4 - Oil Filler Plug

❑ 15 Nm

❑ Replace after removing

❑ With permanent seal

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

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5 - Seal

❑ For the right flange shaft

❑ Replace with manual transmission installed with bevel box. Refer to

⇒ “2.2 Right Flange Shaft Seal, Replacing”, page 373 .

6 - Bleed Pipe

❑ For bleeding the bevel box

❑ Press it in until it stops

7 - Cap

❑ For bleeding the bevel box

8 - Vent Pipe

❑ 10 Nm

❑ Bevel box venting approximately through 12/2005

❑ Allocate the parts according to the Parts Catalog

9 - Bolt

❑ 5 Nm

10 - Heat Shield

❑ Not equipped for all bevel boxes

❑ The contour may be different from the illustration

❑ Allocate the parts according to the Parts Catalog

11 - Right Flange Shaft

❑ Removing and installing. Refer to ⇒ “2.2 Right Flange Shaft Seal, Replacing”, page 373 .

12 - Seal

❑ remove to replace needle bearing (polygon bearing -item 13- ⇒ Item 13 (page 378) )

13 - Needle Bearing (Polygon Bearing)

❑ Replacing. Refer to

⇒ “3.5 Needle Bearing (polygon bearing) on Right Flange Shaft and Seal on Right Flange Shaft, Re‐

placing”, page 387 .

14 - Circlip

❑ Replace after removing

❑ For the needle bearing (polygon bearing)

❑ Insert into the surrounding right flange shaft groove

15 - Hex Nut

❑ 480 Nm

❑ Removing. Refer to ⇒ Fig. ““Unscrew Hex Nut for Output Flange.”“ , page 383 .

❑ Install with Locking Compound - D 000 600- .

❑ Installing. Refer to

⇒ Fig. ““Coat Threads of the New Hex Head Nut with Locking Compound -D 000 600- .”“ , page 387 .

16 - Output Flange

❑ Removing and installing with bevel box removed. Refer to

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

17 - Cap

❑ Lock with the output flange

18 - Shim

❑ Determining the thickness when replacing the output flange. Refer to

⇒ “3.4 Output Flange, Replacing and Selecting New Shim for Output Flange, Bevel Box Removed”, page

387

19 - Seal

❑ For output flange

378

Rep. Gr.39 - Final Drive and Differential

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

6-Speed Manual Transmission 02Q - Edition 05.2013

❑ Replace with bevel box removed. Refer to

⇒ “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

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6-Speed Manual Transmission 02Q - Edition 05.2013

Attach the Bevel Box to the Manual Transmission as Follows:

– Slide on bevel box completely on manual transmission, while

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- .

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– Coat the outer circumference of the new seal with transmis‐

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

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Press Piece - Multiple Use - VW454-

♦ Press Piece - Multiple Use - VW455-

♦ Press Plate - VW401-

♦ Two M8 x 30 mm stud bolts or Guide Pins - M8 - T10273-

♦ Removal Device Pin 2 - VW460/2-

♦ Sealing Grease - G 052 128 A1-

♦ Locking Compound - D 000 600-

♦ Only for seal in pinion housing. Refer to

⇒ 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- .

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Rep. Gr.39 - Final Drive and Differential

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

6-Speed Manual Transmission 02Q - Edition 05.2013

Unscrew Hex Nut for Output Flange.

A - 36 mm Socket for 3/4 Inch Drive

– Pivot the bevel box so that the output flange faces upward.

– Remove the output flange and the inner race/tapered roller

bearing from the bevel box shaft bevel gear.

A - Puller Three-Arm , for example Three-Arm Puller - 45-2-

– Please note the different installation locations for the output

flange seals:

The Output Flange Seal -arrow- is Inside the Pinion Housing.

Output flange seal in pinion housing, removing and installing. Re‐

fer to

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

Installing”“ , page 384 .

The Seal -arrow- is Located on the Output Flange.

Output flange seal, removing and installing. Refer to

⇒ Fig. ““Output Flange Seal -arrow- Removing and Installing:”“ ,

page 385 .

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

383

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6-Speed Manual Transmission 02Q - Edition 05.2013

Output Flange Seal in Pinion Housing, Removing and Installing

Seal, Removing

– Remove output shaft seal -A-.

•

The inner race/tapered roller bearing must be removed from

the output flange:

– Place the Press Piece - Multiple Use - 40-105- on the output

flange.

– Remove the inner race/tapered roller bearing from output

flange with the Tapered Roller Bearing Puller - VAG1582- .

Note

Instead of the Puller - Taper Roller Bearing - Adapter 6 -

VAG1582/6- , the Puller - Taper Roller Bearing - Adapter 6A -

VAG1582/6A- can be used.

Install Seal and Output Flange

– Cover pinion housing with a lint-free cloth.

– Clean any remaining locking fluid from the thread on the shaft

bevel gear.

•

If the shim -2- is removed during the removal of the output

flange, place it back in the pinion housing.

•

This will maintain the bearing pre-load on the shaft bevel gear

-1- inside the pinion housing.

– Insert the previous inner race/tapered roller bearing -3- in the

outer race/tapered roller bearing into the bevel box.

– Lightly lubricate the outer circumference of the new output

flange sealing ring -4-.

– Drive in the new seal using Seal Installer - Flange Shaft -

T10049- .

•

The seal must be flush with the upper edge of the housing.

– Fill the space between the sealing/dust lip halfway with Seal‐

ing Grease - G 052 128 A1- .

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the output flange using the Two-Arm Puller -A-.

A - Two-Arm Puller , for example Puller - Kukko 2-Arm -

70-180mm - 20/10-

Note the following:

•

Do not use a damaged extractor hook.

The output flange may not be on edge when pulling out the

shaft bevel gear.

•

Mount the hooks on the bottom of the pinion housing.

Tension the removal hook with the Two-Arm Puller -arrows-.

Do not bend the removal hook toward the outside.

Interrupt the procedure if necessary, remove the output flange

again and repeat the process.

Output Flange Seal -arrow- Removing and Installing:

Seal, Removing

•

When removing the output flange seal, the inner race/tapered

roller bearing must also be removed.

– Place the Press Piece - Multiple Use - 40-105- on the output

flange.

– Remove the inner race/tapered roller bearing from output

flange with the Tapered Roller Bearing Puller .

– Remove the output flange seal.

Seal, Installing

•

First remove the pinion housing -1- along with the shaft bevel

gear -2- in order to install the seal:

– Remove the bolts for the pinion housing -1-; and carefully re‐

move the pinion housing diagonally of the protruding edges.

– Remove the pinion housing and the shaft bevel gear -2-.

– Clean the thread on the shaft bevel gear.

•

If the shim -3- was also removed during the removal of the

output flange, it must be placed back in the pinion housing.

•

This will maintain the bearing pre-load on the shaft bevel gears

inside the pinion housing.

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

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Place the old inner race/tapered roller bearing -1- into the pin‐

ion housing.

– Lightly lubricate the outer diameter of the new output flange

seal -2-.

– Drive in the new seal using Seal Installer - Flange Shaft -

T10049- .

•

The seal must be flush with the upper edge of the housing.

– Fill the space between the sealing and dust lip of the seal half‐

way with Sealing Grease - G 052 128 A1- .

– Press in the output flange along with the pinion housing and

shaft bevel gear all the way.

•

The shoulder -arrow- of the Press Piece - Multiple Use -

VW455- points to the shaft bevel gear.

– Install the M 8 X 30 mm stud bolts = -A- or Guide Pins - M8 -

T10273- into the axle drive housing.

– Slide a new O-Ring -1- onto the pinion housing -2-.

The pinion housing -2- and shim -3- only fit in one position.

– Install the previous shim -3-.

– Carefully install the pinion housing diagonally all the way with

Removal Device - Pin 2 - VW460/2- .

There is very little space between the pinion housing and the

bevel box housing.

The gap is closed when the pinion housing is tightened.

– Tighten the bolts for the pinion housing -2- diagonally.

Tightening Specification -item 21- ⇒ Item 21 (page 379) .

Continuation for All

386

Rep. Gr.39 - Final Drive and Differential

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

6-Speed Manual Transmission 02Q - Edition 05.2013

Coat Threads of the New Hex Head Nut with Locking Compound

- D 000 600- .

– Tighten new output flange hex head nut.

Tightening Specification -item 15- ⇒ Item 15 (page 378) .

A - 36 mm Socket for 3/4 Inch Drive

– 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 .

3.4

Output Flange, Replacing and Selecting

New Shim for Output Flange, Bevel Box

Removed

– Remove the output flange and, if necessary, remove the inner

race/tapered roller bearing from the output flange. Refer to

⇒ “3.3 Bevel Box Output Flange Seal, Replacing (Bevel Box

Removed)”, page 381 .

This adjustment is necessary whenever the output flange is being

replaced. This creates the preload on the tapered roller bearing

for the shaft bevel gear.

– Measure the length of the shaft on the old and new output

flange to get the difference.

Example:

Old output flange

New output flange

Difference

42.90 mm

43.00 mm

0.10 mm

If the new output flange is longer- install a thinner shim.

If the previously mentioned output flange is longer- install a thicker

shim.

Allocation. Refer to the Parts Catalog.

– Install the output flange. Refer to

⇒ “3.3 Bevel Box Output Flange Seal, Replacing (Bevel Box

Removed)”, page 381 .

3.5

Needle Bearing (polygon bearing) on Right Flange Shaft and Seal on Right

Flange Shaft, Replacing

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

387

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

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Special tools and workshop

equipment required

♦ Press Plate - VW401-

♦ Press Plate - VW402-

♦ Press Piece - Rod -

VW407-

♦ Press Piece - Multiple Use

- VW412-

♦ Bearing Installer - Rear

Wheel Bearing Kit -

VAS3253-

♦ Bearing Installer - Needle

Bearing - T10047-

♦ Seal Installer - Crankshaft - VW204B-

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6-Speed Manual Transmission 02Q - Edition 05.2013

♦ Press Piece - Bushing - VW434-

♦ Puller - Flanged Shaft - T10037-

♦ Socket And Extended Bit - T10107A-

3.5.1

Removing

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 .

– Remove the right front wheel.

– Remove the noise insulation under the engine/transmission, if

equipped. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise In‐

sulation .

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

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– Remove the driveshaft heat shield from the bevel box

-arrows-.

– Remove the right driveshaft. Refer to ⇒ Suspension, Wheels,

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

Vehicles with a Particulate Filter

– Remove the nuts -1 and 2- and then remove the particulate

filter bracket.

Continuation for All

– Place the drip tray under the transmission.

– Remove the right flange shaft bolt -arrow 1- with the Socket

And Extended Bit - T10107A- and install two bolts in the flange

and counterhold the flange shaft with the pry bar.

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– Tighten the Puller - Flanged Shaft - T10037- on right flange

shaft.

Note

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

– Install the right flange shaft.

Attach the Bearing Installer - Needle Bearing - T10047- , as

shown in the illustration, to the flange shaft.

•

The markings “B” on both parts face each other.

The depressions -arrows- must be under the bearing.

– Bolt the parts together all the way.

– Remove the locking ring -A- out of the needle bearing.

– So that the bearing contact surface on shaft is not damaged,

shaft must be rotated during the pressing procedure -arrow-.

– Remove the old seal -A- from the groove -arrow-.

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

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3.5.2

Installing

– Coat the new seal -A- with transmission fluid and insert it into

the groove -arrow- of the flange shaft.

Note

Make sure seal is not tilted.

– Attach the Bearing Installer - Needle Bearing - T10047- to the

flange shaft. Refer to ⇒ page 391 .

– So that the bearing contact surface on shaft is not damaged,

shaft must be rotated during the pressing procedure -arrow-.

– Secure the needle bearing with a new circlip.

– Carefully install the flange shaft while rotating it at the same

time.

– Install flange shaft with a screw and tighten to tightening spec‐

ification ⇒ Item 13 (page 401) .

Install in reverse order of removal.

Vehicles with a Particulate Filter

– Install the particulate filter bracket. Refer to ⇒ Rep. Gr. 26 .

Continuation for All

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

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

– Attach the right driveshaft heat shield to the bevel box

-arrows- and tighten it to the tightening specification. Refer to

⇒ “9.1.3 Tightening Specifications”, page 201 .

– 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 .

– Install the right front wheel. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 44 ; Wheel Installation Tightening Specifi‐

cations .

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Rep. Gr.39 - Final Drive and Differential

FinalDriveandDifferential -> 3 Overview - Seals, Flange Shaft Bearing and Output Flange Bearing inside the Bevel Box for Your Volkswagen Jetta 4 Door Fourth Generation (1999-2005)

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