Removal and Replacement
Bevel gear transfer case (vehicles with 4-cylinder engine), removing and installing, 02M/02Y, 5 & 6 Speed M/T, AWD
Special tools, testers and auxiliary items required
^ Ball joint puller 3287 A
^ Socket V.A.G 1669
^ Old oil collecting and extracting device V.A.G 1782
Removing
- On vehicles with 1 charge air cooler, remove air guide pipe to charge air cooler at lower right of long-member.
TT Coupe:
- Remove sound insulation on center - mounting parts 1 3 -.
TT Roadster:
- Loosen mounting parts in wheel housing at left and right.
- Remove bolts - arrows 1 3 -.
Note: Disregard - arrows A, B -.
All:
- If installed, remove mounting components of exhaust system from subframe.
- Disconnect exhaust system at double clamp - arrows -.
- Slide double clamp toward rear.
- Mark position of flexible disc to bevel gear transfer case flange.
- Unbolt driveshaft from flexible disc at bevel gear transfer case flange - arrows -.
Note: To remove bolts counterhold at triangular flange using a lever.
- Press driveshaft horizontally toward rear as far as possible.
Note: After removing bolts - A - (following illustration N34-0887), engine/transmission assembly moves slightly forward.
CAUTION! Make sure not to damage seal - arrow - in flange of drive axle when removing and installing. If seals are damaged, driveshaft must be replaced.
- Unbolt pendulum support at subframe - arrows A -.
- Carefully press engine/transmission assembly forward.
- Remove nut - arrow - for coupling rod at right stabilizer.
- Remove nut at top of right ball joint.
- Position ball joint puller 3287 A, as depicted in illustration, and pull off ball joint.
Note: To protect ball joint thread, leave nut on a few turns.
- Turn steering toward left.
- Remove heat shield for right drive axle from bevel gear transfer case - arrows -.
- Unbolt right drive axle from transmission flanged shaft.
- Bring right drive axle upward and secure with wire.
- Place old oil collecting and extracting device V.A.G 1782 beneath transmission.
- Remove drain plug - arrow 2 - and drain gear oil.
- Remove bolt for right flange shaft - arrow 1 - using hex extension V.A.G 1669.
Vehicles with cast bracket for bevel gear transfer case:
- Remove bolts - A to C - at bevel gear transfer case bracket.
Note: The bracket cannot be removed at this stage. Leave bracket in installed position.
Vehicles with metal bracket for bevel gear transfer case:
- Remove bolts - A to C - and remove bevel gear transfer case bracket.
All:
- Remove bevel gear transfer case/manual transmission connecting bolts.
- Press bevel gear transfer case off of manual transmission.
- Remove bevel gear transfer case.
Installing
Installation is performed in reverse order of removal. Note the following:
- Always replace O-ring for sealing of bevel gear transfer case/manual transmission - arrow A - and seals for oil supply bores -arrows B and C -.
- Lightly oil O-ring and seals when installing.
- Slide on bevel gear transfer case completely on manual transmission, while doing this join splines of input shaft/bevel gear transfer case centrally with connecting sleeve/differential.
^ With proper tooth position and central guiding, bevel gear transfer case slips up to stop against manual transmission.
Note: Do not pull bevel gear transfer case with mounting bolts against manual transmission, otherwise bevel gear transfer case is canted and mounting eyelets can break off.
- Insert bevel gear transfer case bracket before screwing in connecting bolts for bevel gear transfer case/transmission.
- Tighten new bevel gear transfer case/transmission connecting bolts.
Vehicles with cast bracket for bevel gear transfer case:
- Loosely screw in bolts - A to C - of bracket for bevel gear transfer case.
Vehicles with metal bracket for bevel gear transfer case:
- Loosely screw in bolts - A to C - of bracket for bevel gear transfer case.
All:
- Tighten bolt for right flange shaft - 1 - using hex extension V.A.G 1669.
- Bolt on drive axle to transmission flange shaft.
- Install right drive axle heat shield - arrows -.
- Press engine/transmission assembly to bulkhead; while doing so, carefully guide pin of bevel gear transfer case into drive axle flange.
- Press drive axle horizontally onto guide pin.
CAUTION! Sealing ring - arrow - in drive axle flange must not be damaged when removing and installing. If seals are damaged, drive axle must be replaced.
- Bolt pendulum support on subframe - arrows A -.
- Use new bolts when securing.
- Bolt driveshaft to flexible disc at bevel gear transfer case - arrows -.
- Install exhaust system tension-free.
- Install ball joint and coupling rod.
- Top off gear oil in manual transmission with bevel gear transfer case.
Replace bolts.
45° corresponds to one eighth rotation.
90° corresponds to one quarter rotation.