SEAT Workshop Service and Repair Manuals

Installation

–  Locate in their positions in the gearbox casing: the layshaft -1- together with the control rod with forks for 1st and 2nd gears -2-. –  Insert reverse gear -3- onto the reverse gear shaft -4- and fit in its position in the gearbox casing.

–  Lift the layshaft -1- slightly, together with the control rod with fork for 1st and 2nd gears -2- and replace together with the input shaft -3- and the control rod with fork for 3rd and 4th gears -4-.   Note! It will be necessary to lift the reverse gear slightly when lifting the layshaft. –  Line up the theaded hole in the reverse gear shaft with its corresponding hole in the gearbox casing.

–  Secure the reverse gear shaft with the bolt -arrow- and tighten to 35 Nm.

–  Place the connection rod -1- beside the reverse gear control rod -2-.   Note! It will be necessary to keep the reverse gear slightly lifted.

–  Secure the connection rod with the bolt -arrow- and tighten to 35 Nm.

–  Fit the control rod for 5th gear -1- and bolt up to 35 Nm.

–  Locate the control rods -A- in neutral position (all the control rods must line up). –  Fit the gear console -B-with the bush and securing bolt -arrow-. –  Line up the gear console -B- with the control rods; to do this fit the connection shaft -C- and tighten the bolt -arrow- to 15 Nm. –  Remove connection shaft -C-.

–  Fit selector finger -1- in the gear console -2-.

–  Fit the spring -arrow- between the selector finger -1- and the gear console -2-. –  Locate the connection shaft -3- in the selector finger and the gear console. Fitting position The step on the connection shaft should be facing the gear shafts. –  Check that the connection shaft -3- fits perfectly in the gear console -2-. –  Insert cap -4- flush with the gearbox casing. –  Adjust the selector finger and the control bush when any of these components have been replaced: l  Selector finger l  Control bush l  Selector rod or bracket l  Clutch housing l  Gearbox casing Adjusting the selector finger and the control bush → Chapter. –  Fit the differential to the gearbox casing. –  Check that the magnet is not broken or cracked and place in its housing in the gearbox casing. –  Secure the magnet with -AMV 100 200 03- paste. –  Thoroughly clean the contact surfaces of the clutch housing and the gearbox casing. Apply a uniform layer (not too thick) of -AMV 188 200 03- sealing paste. –  Fit the clutch housing to the gearbox casing. –  Check that the selector finger fits into the control bush. –  Bolt up the clutch housing to the gearbox casing to 25 Nm tightening torque. –  Bolt up the reversing light switch to 20 Nm

–  Fit thrust washer, pressure springs, conical rings and flanged shafts.   Note! Do not mix up left and right-hand flanged shafts. They are not interchangeable.

Item	Flanged shaft	Dimension “a”
1	left-hand side of gearbox casing	57 mm
2	right-hand side of gearbox casing	48 mm

–  Fit articulation flange bolts with tool -T20005- to a tightening torque setting of 25 Nm.

–  Fit 5th gear onto the input shaft. Use tool -U-40200/20-. Fitting position The projection on the interior diameter of the gear should be facing the gearbox casing.

–  Fit up the new securing bolt with a new plate spring for the 5th gear. Fitting position The concave side of the spring washer should be facing the 5th gear. –  Do not tighten the securing bolt yet.

–  Fit the thrust washer for 5th gear -1- onto the layshaft. Assembly position The projection in the internal diameter of the thrust washer should be facing the roller bearing. Fit the needle bearing bush -2- as described below: –  Heat the bush to about 100 °C with the electric blower -SAT 1416-, on a heating plate. –  Use tool -U-40200/15- to fit the bush. –  Fit the needle bearing.

–  Fit the sliding 5th gear -1-. –  Fit the syncromesh -2- on the 5th sliding gear. –  Check that the spring -arrow- is fitted to the syncromesh ring. If this is not the case, fit it.

Assembly position of 5th gear syncromesh hub The highest collar dimension-a-and the sharpest bevel -arrow-, should be facing the sliding 5th gear.

–  Fit 5th gear syncromesh hub to secondary shaft with tool -U-40200/15-.   Note! t  The syncromesh locking keys -arrow- must coincide with the housings in the hub. t  Once the syncromesh hub is fitted, check that the syncromesh ring turns freely.

Find the correct 5th gear safety ring There are several safety rings -2- of different thicknesses, to secure the 5th gear syncromesh hub -1-. –  Determine the thickness of the new ring -2- meauring the shaft groove with a feeler gauge. –  Select the best fitting safety ring from the following table.

Thickness (mm)	Spare no.
2.00	085 311 187
2.10	085 311 187 A
2.20	085 311 187 B
2.30	085 311 187 C
2.40	085 311 187 D
2.50	085 311 187 E
2.60	085 311 187 F

–  Fit a new safety ring -1- making sure it is perfectly seated. –  Compress pin -2- and fit the control rod for the 5th gear.

–  Fit the sliding sleeve onto the 5th gear syncromesh hub. Assembly position The pointed teeth -arrow A- should be facing the 5th gear, and the tooth marks -arrow B- should coincide with the cut-outs in the hub.

–  Tighten bolt -A- for 5th gear to 40 Nm. To do this engage 5th gear, moving the sliding sleeve down -arrow 1- and also the 2nd gear by turning the selector shaft -arrow 2- and pulling outwards -arrow 3-. –  The input and layshafts will be locked as two gears are engaged; the syncromesh and 5th gear will not turn. –  Remove the sliding sleeve again. –  Fit the sliding sleeve with the fork for 5th gear.

–  Loosen the locknut on the dome headed bolt -1-. –  Fit the dome headed bolt into its location in the gearbox casing.   Note! If necessary, first clean the threaded hole with an M8×1 tap. –  Adjust the sliding sleeve and the fork for the 5th gear → Anchor. Adjust the sliding sleeve and the fork for the 5th gear –  Select neutral (all the rods should be lined up). –  Coat the thread of the dome headed bolt with locking fluid -D 000 600 A2-.

–  Loosen the locknut -1- on the dome headed bolt -2-. –  Turn the dome headed bolt -2- until the sliding sleeve is located at the same height as the syncromesh hub. –  Select 5th gear. –  Screw in the dome headed bolt -2- until the fork has no axial play in the sliding sleeve groove.

–  Loosen the dome headed bolt approx. 1/8 of a turn -2- to create the correct play between the sliding sleeve and the 5th gear fork. –  Lock the dome headed bolt -2- with the locknut -1- tightening it towards the gearbox casing.   Note! On tightening the locknut -1- do not allow the dome headed bolt -2- to move. Keep it immobile with a spanner. –  Deselect 5th gear. –  Check that the sliding sleeve is in neutral an the syncromesh ring turns freely. –  Fit the gearbox casing cover gasket. –  Fit the cover to the gearbox casing and tighten the securing bolts to 10 Nm.