SEAT Workshop Service and Repair Manuals

Dismantling

• ‒ → Mount gearbox on repair stand.

Note:

Use M12 x 1.5 x 30 hexagon bolts (arrows).

• ‒ Drain gearbox oil.

• ‒ → Remove selector shaft/selector gate with selector cover, to do this bring selector shaft to neutral.
• ‒ Unscrew bolts (arrows) and pull selector shaft/selector gate out from gearbox housing.

• ‒ → Pull out spring pin (arrow 1) with side cutting pliers.
• ‒ Pull out guide bush with speedometer drive (arrow 2).

• ‒ → Remove gearbox housing securing bolts -B- on clutch housing.

Note:

Do not drive dowel pins out (arrow).

• ‒ → Lever clutch housing off by levering alternate sides (arrows).

• ‒ → Remove differential gearbox, to do this swing output shaft slightly to one side.

• ‒ → Pull 3rd/4th gear selector rod and 1st/2nd gear selector rod out (-1-).
• ‒ Remove1st/2nd gear selector fork (-2).
• ‒ Remove magnetic washer (-3-).

• ‒ → Remove bolts (arrow A) for mounting bracket (arrow D).
• ‒ Swing input shaft (arrow C) and output shaft (arrow B) to side (arrow), mounting bracket must lift.

• ‒ → Swing input and output shafts to side (arrows).
• ‒ Swivel 3rd/4th gear selector fork and remove (arrow A).
• ‒ Swivel 5th/reverse gear selector fork and remove (arrow B).
• ‒ Take input and output shafts out from gearbox housing together.
• ‒ Take mounting bracket and reverse wheel with needle roller bearing and thrust washer out.

Assembling

• ‒ → Locally manufacture an assembly hook for reverse gear.

• Wire thickness 3 mm
• Dimension -a- 205 mm
  Dimension -b- 15 mm
  Dimension -c- 35 mm
  Dimension -d- 30 mm

• ‒ → Assemble reverse wheel as follows:
• ‒ Insert lower thrust washer (item1).
  Installation position: Tab (arrow) towards gearbox housing
• ‒ Slide needle roller bearing (item 2) onto shaft for reverse wheel.
• ‒ Insert assembly hook (item 3).
• ‒ Slide reverse wheel (item 4) over needle roller bearing.
  Installation position: Shoulder towards mounting bracket.
• ‒ Insert upper thrust washer (item 5).
  Installation position: Tab towards mounting bracket
• ‒ Fit mounting bracket (item 6).

• ‒ → Insert input shaft (item1) and output shaft (item 2) together.

Note:

Locking collars must be in neutral position.

• ‒ Remove assembly hook (item 3).

• ‒ → Press input and output shafts to side.
• ‒ Insert 5th/reverse gear selector fork (arrow B).
• ‒ Insert 3rd/4th gear selector fork (arrow A).

• ‒ → Insert 1st/2nd gear selector fork (item 2).
• ‒ Slide in selector rods (item1).

Note:

Correctly installed selector rod ends are at same height.

• ‒ → Press mounting bracket (arrow 1) downwards until into position.
• ‒ Coat bolts (arrow 2) with locking fluid D 000 600 and tighten.

• ‒ Install differential.
• ‒ → Coat cleaned gearbox housing sealing surface evenly with sealant AMV 188 200 03.

• ‒ → Fit clutch housing to gearbox housing, when doing this ensure the dowel pins -A- are seated securely.

Notes:

• ◆ Do not turn gearbox housing, insert bolts from below.
• ◆ When replacing drive dowel pins -A- in onto stop.

• ‒ Tighten housing bolts -B- diagonally.

• ● The gear stick lever must rest in neutral in the 3rd/4th gate.

• ‒ → Coat with sealant AMV 188 200 03.
• ‒ Insert gearbox side selectors complete.
• ‒ Tighten bolts (arrows).

• ‒ → Select 4th gear (arrow).

→ Checking friction moment

A - Commercial torque gauge 0 ... 600 Ncm

B - Extension for 1/2 " square drive socket

Note:

The friction moment must not exceed 1.5 Nm, otherwise repeat all measurement sequences and change adjustment washer thickness.

• ‒ → Fit speedometer drive (arrow 1).
• ‒ Drive in spring pin (arrow 2) as far as the stop.