Bevel Box: Notes

Special tools and workshop equipment required

Oil Collecting and Extracting Device V.A.G 1782
Socket and Extended Bit T10107
Bracket 2024 A /1

Removing

-- Remove the noise insulation. Refer to Removal and Installation .

Fig 1: Center Noise Insulation Bolts

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NOTE:

Depending on the version, different noise insulation may be installed.

-- Remove the front section of the right wheel housing liner. Refer to Removal and Installation .

Fig 2: Identifying Fasteners

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NOTE:

Depending on the version, different wheel housing liner may be installed.

-- Remove the holder for the exhaust system from the aggregate holder -arrows-.

Fig 3: Bracket For Exhaust System

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-- Separate the exhaust system at the clamping sleeve -arrows-.

Fig 4: Disconnecting Exhaust System At Double Clamp

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-- Tie up the exhaust pipe.

NOTE:

To prevent damage, the decoupling element on the front exhaust pipe must never be angled more than 10°.

-- If installed, remove left front level control system sensor -G78- -arrows-.

Fig 5: Installing Front Level Control System Sensor

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-- Disconnect the connector -1- on the oil level thermal sensor -G266-.

Fig 6: Disconnecting Connector From Oil Level Thermal Sensor G266

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-- Remove the bolts -2- and -3-.

Fig 7: Identifying Pendulum Support & Bolts

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NOTE:

Ignore bolt -1-.

-- Mark the position of driveshaft with flexible disc to bevel box flange.

Fig 8: Driveshaft Flexible Disc

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-- Remove the driveshaft and flexible disc from the bevel box flange shaft -arrows-.

NOTE:

In order to loosen the bolts, hold a lever against the driveshaft flange/final drive.

-- Slide front driveshaft tube as far back as possible.

CAUTION:

Sealing ring -arrow- in driveshaft flange must not be damaged when removing transmission. If seal is damaged, driveshaft must be replaced.
When loosening pedal support/subframe bolts, engine/transmission assembly moves forward slightly.

Fig 9: Identifying Sealing Ring In Driveshaft Flange

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-- Remove the bolts -2- and -3-.

Fig 10: Identifying Pendulum Support & Bolts

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-- Push the aggregate forward slightly and remove the driveshaft from the bevel box.

-- Lift up driveshaft and secure with wire.

Vehicles with 6-Cylinder 3.2L Engine:

Fig 11: Identifying Right Driveshaft Heat Shield And Bevel Box

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-- Remove the right drive axle heat shield from bevel box -arrows-.

-- Remove the bolts on the bevel box -1- and engine -2-.

Fig 12: Bevel Box Bracket & Bolts

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-- Remove the bevel box bracket -A-.

4-Cylinder 2.0L TFSI Vehicles:

-- Remove the right drive axle heat shield from bevel box -arrows-.

Fig 13: Drive Axle Heat Shield

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-- Remove the catalytic converter support by removing the bolts -1- and -2- if applicable.

Fig 14: Front Exhaust Pipe With Catalytic Converter Support Bolts And Font Exhaust Nuts

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-- Remove the bolts on the bevel box -arrows 1- and engine -arrows 2-.

Fig 15: Identifying Oil Level Thermal Sensor Bolts

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-- Remove the bevel box bracket.

All Vehicles:

-- Remove the right front wheel.

-- Remove the right drive axle from the flange shaft on the bevel box.

-- Remove the bolt -arrow- for the right ball joint. Refer to Removal and Installation .

Fig 16: Ball Joint Lower Nuts

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-- If equipped, remove the left front level control system sensor nuts.

-- Remove the ball joint from the control arm.

NOTE:

The installation position on the left front wheel suspension is shown in the illustration.

-- Move the right suspension strut to the outside and support it with the 2024 A /1 as illustrated.

Fig 17: Supporting Right Suspension Strut With Tool 2024 A/1

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WARNING:

There is the risk of an accident due to loose support parts.

Secure the securing pin and control arm with the plug connector -arrow- and nut -1-.

NOTE:

The installation position on the left front wheel suspension is shown in the illustration.

-- Lift up right drive axle and secure with wire.

-- Tighten the subframe crossmember before removing. Refer to Removal and Installation

-- Place the V.A.G 1782 under the transmission.

-- Remove right flange shaft bolt with T10107 by installing 2 bolts in flange and counter holding flange shaft with assembly lever.

Fig 18: Identifying Right Flange Shaft Countersunk Bolt, Socket And Key T10107

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-- Remove the bevel box bolts -arrows- on the transmission.

Fig 19: Identifying Special Tools And Workshop Equipment Required Bolts

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-- Remove bevel box from transmission together with right flange shaft.

Installing

Install in reverse order, paying attention to the following:

Tightening Specifications

Refer to FLANGE SHAFTS, SHAFT SEALS OVERVIEW .
Bevel box bracket for vehicles with four-cylinder, 2.0L TFSI - Tightening specification and sequence" FLANGE SHAFTS, SHAFT SEALS OVERVIEW => Bevel Box Bracket for Vehicles with 4-Cylinder, 2.0L TFSI - Tightening Specification and Sequence .
Bevel box bracket for vehicles with six-cylinder, 3.2L engine FLANGE SHAFTS, SHAFT SEALS OVERVIEW => Bevel Box Bracket -A- for Vehicles with 6-Cylinder 3.2L Engine - Tightening Specification and Sequence .
Refer to IDENTIFYING RIGHT DRIVESHAFT HEAT SHIELD AND BEVEL BOX .

NOTE:

When installing, bring all cable ties back to same positions.

-- Place bevel box together with flange shaft on transmission and rotate flange shaft.

NOTE:

Make sure the sealing ring on the transmission is not damaged.

-- Attach bevel box to transmission with four new bolts.

-- Attach the bracket to the engine and the bevel box.

-- Install the subframe. Refer to Removal and Installation .

NOTE:

Sealing ring -arrow- in driveshaft flanges must not be damaged when removing and installing. If seal is damaged, driveshaft must be replaced.

Fig 20: Identifying Sealing Ring In Driveshaft Flange

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Slip driveshaft horizontally onto respective guide pin.

During removal, pay attention to the markings on the driveshaft and flange. These must be aligned with each other -arrows-.

Fig 21: Aligning Markings On Driveshaft At Flange Of Haldex Clutch

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-- Secure the driveshaft with flexible disc on the bevel box flange -arrows-. Refer to FINAL DRIVE, DIFFERENTIAL .

Fig 22: Identifying Bevel Gear Transfer Case Flange Bolts

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-- Install the right flange shaft. Refer to RIGHT FLANGE SHAFT .

-- Install pendulum support. Refer to SUBFRAME MOUNT OVERVIEW .

Fig 23: Identifying Pendulum Support & Bolts

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-- Install the right drive axle. Refer to Removal and Installation .

-- Install the exhaust system free of tension. Refer to [For engine(s) CBRA] Description and Operation or to [For engine(s) CCTA] Description and Operation .

-- Refer to OIL LEVEL IN BEVEL BOX, CHECKING AND TOPPING OFF .