SEAT Workshop Service and Repair Manuals

Bevelled gear, removing and installing Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Extractor -SAT 1100-, see equivalent → Anchor

t	Torque wrench kit -SAT 8010-, see equivalent → Anchor

t	Socket and key -T10107-

Removal: –  Move selector lever in vehicle to »P« position. –  Raise vehicle. All 4 supports of lifting platform must be at same height. –  Remove front right wheel.

–  Remove centre noise insulation -attachment parts 1 and 2-.

–  Remove soundproofing (right-side) -fasteners 1 ... 3-.

–  Unscrew the insulating panel for the right half shaft from its mounting at the bevelled gears -arrows-. –  Unscrew the right and left hand side cardan shafts from the flanged shafts.

–  Push the right articulated shaft forwards and fix to the longitudinal member -arrow- with a belt as illustrated in the figure.

–  Remove exhaust system bracket from subframe -arrows-.

–  Detach connector -1- from oil level and oil temperature sender -G266 -.

–  Unscrew bolts of the pair of bevelled gears -arrow 1- and unscrew the motor -arrow 2-. –  Mounted to the support for the bevelled gear.

–  Remove the exhaust system by the surrounding sleeve -arrows-. –  Tie up the front exhaust pipe.   Note The vibration damper on the front section of the exhaust pipe with particle filter should not be bent by more than 10° otherwise there is a risk of damage.

–  Mark position of propshaft with flexible coupling in relation to bevel box flange. –  Unscrew the cardan shaft with flexible disk from the pair of bevelled gears -arrows-.

–  Press propshaft horizontally to rear as far as possible.   Caution t  When removing the gearbox, make sure the seal -arrow- on the cardan shaft flange is not damaged. If seal is damaged propshaft must be renewed. t  Slackening off bolts for pendulum support/subframe causes engine/gearbox assembly to swing forwards slightly.

–  Unscrew bolts -2- and -3-. –  Press the unit to the front a little and separate the cardan shaft from the pair of bevelled gears. –  Tie up the cardan shaft with a belt.

–  Remove subframe. For information on how to remove the -subframe-, refer to → Rep. gr.40. If the job is done correctly, the subframe can be removed and reinstalled without subsequently causing increased tyre wear, which may lead to customer complaints. It is recommended to read this information »before« removing gearbox. Then the position of the -subframe- can be properly fixed and the subframe removed. –  Place used oil collection and extraction unit -SAT 1100- below gearbox.

–  Using socket and extended bit -T10107 -, remove bolt securing flange shaft (right-side). To do so, screw two bolts into flange and counterhold flange shaft with suitable lever.

–  Remove the bolts -arrows- of the pair of bevelled gears from the gearbox. –  Remove the pair of bevelled gears together with the right flange shaft from the gearbox. Installation Installation is carried out in the reverse sequence; note the following:   Note All cable ties which are released or cut open during removal must be fitted in the same position when installing. –  Push bevel box together with flange shaft onto gearbox while turning flange shaft.   Note Take care not to damage the gearbox in doing so. –  Screw the bevelled gear to the gear box using four new bolts. Tightening torque → Chapter –  Screw the bracket of the pair of bevelled gears to the engine and the bevelled gear, tightening torque and sequence → Anchor. –  Install subframe → Rep. gr.40. –  Press engine/gearbox towards bulkhead panel, carefully guiding bevel box pin into propshaft flange.   Note

t  The seals -arrow- in flanges of the propshaft must not be damaged when removing and installing. Replace the cardan shaft if the seals are damaged. t  Push propshaft horizontally onto guide pin. t  Take note of the markings that were made on the propshaft and flange when removing.

–  Screw the cardan shaft with flexible disk on to the pair of bevelled gears -arrows- → Final drive 0AV and 0BR; Rep. gr.39 .

–  Assemble the pendulum support → Chapter. –  Install exhaust system so it is free of stress → Rep. gr.26. –  Install right drive shaft → Rep. gr.40. –  Pair of bevelled gears oil level: checking and completing → Chapter. Tightening torques

Component	Nm
Heat shield for drive shaft to bevel box	25