SEAT Workshop Service and Repair Manuals

Seal for the output flange of the bevelled gear: Renewing (bevelled gear removed) Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Pressure tool -40-105-, see equivalent → Anchor

t	Tappet -T10049-, see equivalent → Anchor

t	Hose clamp -T20137-, see equivalent → Anchor

t	base -T20172/1-, see equivalent → Anchor

t	Tower -T20172/2-, see equivalent → Anchor

t	Gearbox support -T20172/4A-, see equivalent → Anchor

t	Pipe section -VW 516-, see equivalency → Anchor

t	Extractor -KUKKO 20/10-, see equivalent → Anchor

t	Three clawed extractor kit -Kukko 45-2-, see equivalent → Anchor

t	Torque wrench 100-550 Nm -SAT 8020-, see equivalent → Anchor

t	Adapter -SAT 8020/1-, see equivalent → Anchor

t	Roller bearing bush extractor -V.A.G 1582-, see equivalent → Anchor

t	Bracket -V.A.G 1582/6-, see equivalent → Anchor

t  Universal tool -VW 771-, see equivalent → Anchor

t  Tray -T20173-, see equivalent → Anchor t  Bolts (2x) M10 x 30 t  4 Nuts M12 x 10 Removal:   Note The ring seal for the flange between the pair of bevelled gears can only be replaced with the bevelled gears removed. –  Remove the pair of bevelled gears → Chapter –  Place the pair of bevelled gears over the gearbox support -T20172/4A-. –  Place the tray -T20173- under the bevelled gear. –  Let the oil from the pair of bevelled gears drain out.

–  Immobilise the flange from the bevelled gears with the fastening tool -T20137-. –  Using the torque wrench 100-550 Nm -SAT 8020- and the adaptor -SAT 8020/1- unscrew the hexagonal bolt for the flange. A -  36 Socket for 3/4 inch control –  Turn the pair of gears so that the flange inserted looks upwards   WARNING This flange is positioned relative to the toothed shaft.

–  Mark the flange with respect to the toothed shaft before removing in order to avoid subsequent vibrations in the cardan shaft.

–  Using the three-clawed extractor -Kukko 45-2-, -A- remove the flange from the drive pinion for the pair of bevelled gears.   Note On removing the flange, the inner ring of the roller bearing remain on the flange, and must be removed → Anchor. –  Position the tightening plate -40-105- over the flange.

–  Remove the inner ring of the roller bearing from the flange using the roller bearing extractor -V.A.G 1582-.

–  Remove the seal -A- using the universal tool -VW 771- fro the flange. –  Clean the remains of thread paste from the thread of the drive pinion. Installation

l  Make sure that the shim -2- adjusting the bearing preload of the shaft bevel gear -1- is still fitted. –  Position the inner ring of the roller bearing -3- in the outer ring of the pair of bevelled gears. –  Lightly oil the exterior of the new seal -4- for the flange.

–  Fit new seal as far as it will go using tappet -T10049-. –  Fill space between sealing lip and dustcap halfway with sealing grease → Spare parts catalogue.   Note Ensure the flange is fitted in position, as marked during the removal process, relative to the toothed shaft.

–  Fit the output flange so that the markings -arrow- are aligned.

–  Insert the flange with the extractor -KUKKO 20/10--A-. –  In doing so, position the extractor gripper under the drive pinion casing. –  Apply thread paste to the thread of the new hexagonal nut → Spare parts catalogue. –  Tighten the new hexagonal nut for the flange.

Tightening torque: 480 Nm A -  36 Socket for 3/4 inch control –  Install the bevelled gear → Chapter. –  Check the pair of bevelled gears oil level → Chapter