SEAT Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ VW 309 Holding plate
• ◆ VW 313 Support clamp
• ◆ VW 353 Gearbox support
• ◆ VW 402 Thrust plate
• ◆ VW 412 Press tool
• ◆ VW 415 A Tube

• ◆ VW 401 Thrust plate
• ◆ VW 433 Press tool
• ◆ VW 459/2 Installing and removing tool
• ◆ 2004 Gearbox holder
• ◆ 3250 Support

Dismantling and assembling viscous coupling, pinion housing/shaft bevel gear, input shaft bevel gear, differential, differential lock and freewheel

Dismantling

• ‒ Drain gearbox oil.

Rear final drive with freewheel

• ‒ Remove freewheel lock actuator.

• ‒ → Clamp rear final drive to assembly stand.

To secure the final drive to assembly bracket a new hole is required in gearbox holder VW 353. Modifying gearbox holder VW 353 .

• ‒ Lever off cap for hexagon nut used to secure viscous coupling with a screwdriver.
• ‒ → Take off viscous coupling.

•     A -    Hexagon bolts M 10 x 20
•     B -    Deep socket insert, 27 mm AF

When loosening viscous coupling hexagon nut counter-hold using pipe -C- with special tool 2004 (2nd mechanic).

• ‒ → Remove pinion housing, when doing this screw bolts -A- in evenly so that the housing does not cant.

• ‒ → Remove flange shaft, to do this screw 2 bolts -A- in evenly so that the flange shaft does not cant (illustration shows final drive installed).

•     A -    Bolt M 10 x 100

• ‒ → Pull output shaft drive flange out from differential bevel gear by turning bolt -A- (M 10 x 100) (illustration shows final drive installed).

• ‒ Place chisel or distance piece -B- under drive flange.

If drive flange cants during removal sequence then fit a second bolt into opposing threaded hole for removing.

Rear final drive with freewheel

• ‒ → Remove mounting bolt (arrow) for freewheel switch lever.
• ‒ Remove selector lever for freewheel.

• ‒ → Remove right-hand cover (next to oil filler plug) when doing this screw bolts -A- in evenly so that the cover does not cant.
• ‒ Remove cover together with differential and freewheel if fitted.

Rear final drive with freewheel: When removing cover with differential and freewheel be aware of the balls (Qty. 6).

Rear final drive with freewheel

• ‒ → Take out freewheel components.

•     A -    Selector sleeve
•     B -    Sliding sleeve
•     C -    Spring
•     D -    Balls (Qty. 6)

• ‒ Remove left-hand cover, when doing this note, if fitted, differential lock connecting sleeve.

The removal is identical to removing the right-hand cover => Page 39-144.

• ‒ → Take out bevel gear with input shaft.

Assembling

• ‒ Insert bevel gear with input shaft.

• ‒ Screw in two M 8 studs to locate cover.
• ‒ → Press in cover.
• ‒ Tighten hexagon bolts to torque setting.

Rear final drive with freewheel

• ‒ → Assemble lock for freewheel:
• ‒ Fit balls -A- (Qty. 6) using a thick grease into selector sleeve -B-.
• ‒ Place spring -C- on sliding sleeve -D-.
• ‒ Fit selector sleeve -B- into spring -C-, when doing this note balls -A-.
• ‒ Fit all components together onto input shaft, move sliding sleeve -D- slightly if necessary.
• ‒ Fit spring -E-.

• ‒ → Installation position of freewheel lock:

• A: shown disengaged
  B: shown engaged

•     1 -    Input shaft
• with internally mounted output shaft
•     2 -    Ball (Qty. 6)
•     3 -    Sliding sleeve
• outer machined collar towards spring
•     4 -    Spring, 64.5 mm ø
•     5 -    Selector sleeve
•     6 -    Spring, 46 mm ø
•     7 -    Bolt with conical head
•     8 -    Freewheel

• ‒ Screw two M8 studs in opposite one another to locate cover with differential and if fitted freewheel.
• ‒ → Press in cover.
• ‒ Tighten hexagon bolts to torque setting.
• ‒ Drive in right-hand flange shaft as well as left-hand output shaft drive flange using a synthetic head hammer. First install new securing rings, flange shaft => Page 39-120.

Rear final drive with freewheel

• ‒ → Insert operating mechanism for freewheel lock, then press sliding sleeve in direction of arrow with a screwdriver.
• ‒ Install mounting bolt -A- in rear axle housing to secure operating mechanism.

• ‒ → Freewheel lock operating mechanism installation position:

•     1 -    Operating lever
•     2 -    Seal
•     3 -    Mounting bolt
•     4 -    Expander pin
•     5 -    Selector rod

• ‒ Fit shim(s).
• ‒ Install two M 8 studs opposite one another to locate pinion housing.
• ‒ → Drive in pinion housing with shaft bevel gear or press in.

Installation position:

The bolt-on surface -A- is above the oil filler hole -B-.

• ‒ Tighten hexagon bolts to torque setting.

• ‒ Install viscous coupling.
• ‒ → Tighten centralising nut to torque setting.

•     A -    Hexagon bolts M 10 x 20
•     B -    Deep socket insert, 27 mm AF

When tightening viscous coupling centralizing nut counter-hold using pipe -C- with special tool 2004 (2nd mechanic).

• ‒ Remove rear final drive from assembly bracket.

Rear final drive with freewheel

• ‒ → Slide in actuator and turn 90° upwards.
• ‒ Pull connecting piece out of actuator and hold vacuum connection closed.
• ‒ The actuator should have hooked onto the pin on relay lever, check by pulling on actuator.
• ‒ Push actuator in again and tighten bolts (arrows) to torque setting.