SEAT Workshop Service and Repair Manuals

Removal: –  Remove gearbox → Chapter. –  Mount gearbox on assembly stand → Chapter. –  Place below the collecting tary -T20173-.

–  Unscrew drain plug -arrow- and empty gearbox oil. –  Remove clutch release socket and clutch release prong → Chapter. –  Unscrew guide bush securing bolts → Chapter.   Caution When removing the gearbox casing, some remaining gear oil may drip.

–  Unscrew the bolts -arrows- and remove the gearbox casing cover.

Remove shift fork and selector sleeve for 5th gear as follows: –  Set gearbox prong -1- in neutral position. –  Unscrew bolts -2- for forked bolt on 5th gear. –  Remove bolt on shift fork for 5th gear in direction of -arrows A-. –  Remove the gear prong from the guide -arrow A-. –  Remove the spring -3-. –  Carefully extract the mobile sleeve -4-, removing the locking pins. –  Insert the new mobile sleeve -4- in synchroniser hub.

To loosen mounting bolts -A- on synchromesh element on 5th gear wheel proceed as follows: –  push sliding sleeve for 5th gear downwards -arrow 1-, engaging the gear. Also shift into 1st gear with shift lever -arrow 2- and -arrow 3-. –  The input and output shafts remain locked when two gears are engaged; the synchromesh hub and 5th gear wheel do not turn. –  Slacken and remove bolts -A-.   Note Carefully remove bolt securing agent residues from threaded holes with tap. –  Remove selector sleeve for 5ht gear and locking elements.

–  Remove synchromesh element and 5th gear wheel using the bridge with bollt - U 40100/1-. –  Remove the needle bearing for the 5th gear.   Note t  To remove 5th gear mesh, first heat to approx. 100 ºC with hot air blower -SAT 1416-. t  During removal check that the extractor feet do not bend outwards. Make sure that the 5th gear is not damaged.

–  Remove 5th gear mesh, using the bridge with screww -U 40100/1-.

–  Remove left articulation flange. –  Remove the articulation flange with the spring, thrust washer, and conical ring.

–  Remove the two bolts -arrows- supporting the reverse gear shaft.

For vehicles with start stop system –  Remove the gearbox neutral position sender -G701--arrow-. Continued for all vehicles

–  Place the gear selection drive shaft in neutral. Unscrew mounting bolts -arrows- and remove selector shaft from transmission housing.

–  Remove the cover -A- and the support pins -B- from the lower part of the gear box, previously removing bolts -1- and -2-.

–  Remove support bolts -A- from upper part of gearbox and bolts -B- for securing gearbox casing to clutch casing.

–  Remove bolts -A- to secure the clutch housing to the gearbox casing.   Note Do not remove the nuts -B- for fitting the secondary shaft.

–  Separate gearbox casing by carefully levering and alternating in all ribs protruding from gearbox -arrows-. Do not damage hermetic surfaces.

–  Remove the prongs -A- with the connection guides. –  Remove the bolt -B-, and extract the reverse gear prong.

–  Remove the nuts -B- for fitting the secondary shaft.   Note Placing the gearbox shafts vertically before removing all nuts -B-.

–  Remove clutch casing by order, reverse gear shaft -A-, input shaft -B- and secondary shaft -C-. –  Remove the differential set from the clutch housing.