SEAT Workshop Service and Repair Manuals

Bevel box: removing, all vehicles with turbo diesel engine (Common Rail, 2nd generation) Identification

There is a shoulder -arrow 2- underneath charge air control pressure unit -arrow 1- in upper area of gearbox carrier (gradual introduction). Continuation for all vehicles

Special tools and workshop equipment required

t	Torque wrench -VAG 1331-

t	Counter support -T10371-

t	Socket -T10107A-

t	Support bridge -T10323-

t	Tensioning strap -T10038-

t  Sealing cap -T10381- t  Grease -G 060 735 A2- –  Loosen wheel bolts on front left and front right. –  Raise vehicle. –  Remove front wheels. –  Remove front right wheel housing liner → General body repairs, exterior; Rep. gr.66.

–  Remove pendulum support from gearbox, bolt -1- and bolt -2-.

–  Release the connector -1- from the oil level and temperature sender -G266-. –  If front left vehicle level sender connectors -G78- are present, release them → Rep. gr.40.

–  Remove left and right coupling rods from anti-roll bar → Running gear, axles, steering; Rep. gr.40. –  Unscrew nuts -arrows- for swivel joint on suspension links.

–  Remove exhaust system bracket from subframe -arrows-. –  If present, remove exhaust system support from gearbox. –  Fix position of subframe prior to removal → Running gear, axles, steering; Rep. gr.40. –  Remove subframe using steering box → Running gear, axles, steering; Rep. gr.40.

–  Secure support bridge -T10323- via inner rear threaded holes for the subframe (⇒ next figure). –  Use the subframe securing bolts for this purpose. –  Mark position of propshaft with flexible coupling relative to bevel box flange with paint. –  Unbolt propshaft from bevel box -arrows- → Rep. gr.39.

–  Lie a cloth -A- on the support bridge -T10323-, so as not to damage the propshaft paint. –  Move front section of propshaft to rear up to stop and install the shaft on the support bridge -T10323-.

–  Remove drive shaft heat shield from bevel box (nuts -1-) → Running gear, axles, steering; Rep. gr.40.

–  In the case of an auxiliary heater, remove coolant hoses -1- and -2- for supplementary heater from engine and bevel box. Do not open pipes → Auxiliary heater; Rep. gr.82.

–  Remove drive shaft from bevel box → Running gear, axles, steering; Rep. gr.40. –  Swivel drive shaft into the wheel housing. The surface protection of the shafts must not be damaged. Secure the suspension strut drive shaft using tensioning strap -T10038-. –  Remove engine cover.

–  Remove particulate filter → Rep. gr.26. –  Remove turbocharger support -arrow- → Rep. gr.21 –  Remove bevel box carrier bolts from engine and bevel box -A- and -B-. –  Remove the gearbox support.

–  Remove retaining ring -arrow A- and O-ring -arrow B- from right stub shaft.

–  Remove countersunk bolt for right stub shaft.

–  Remove upper securing bolts -arrows- for joining bevel box to gearbox.

–  Unscrew the bottom bolts -arrows- for fixing the bevel gear to the gearbox. –  Carefully press bevel box off gearbox and remove.

–  Install sealing cap -T10381- on the gearbox.