SEAT Workshop Service and Repair Manuals

Installation l  A new grooved ball bearing has been pressed onto the input shaft → Item.

–  Insert the input shaft -1- as well as the output shaft for 5th / 6th gears and reverse gear -2- together with selector rod -3-, selector fork -4- and reverse shaft -5-. Observe the different mounts for the reverse gear prong.

The reverse gear prong -1- is mounted on the shaft -2- behind the selection shaft of the of the 5th / 6th gear -3- prong.

The reverse gear prong -1- is positioned on the selection shaft of the 5th / 6th gear -2- prong. Continuation for all vehicles   Note

To fit the shafts in the clutch housing, a second mechanic is required. –  Insert the differential in clutch housing -1- –  Using one hand, lift the 1st - 4th gear output shaft -3- upwards together with the selector rods -4- as illustrated. –  Slightly lift the differential. –  At the same time the second mechanic must lift the input shaft as well as the output shaft for 5th / 6th and reverse gear -2- slightly, together with the reverse shaft. –  Now insert the secondary shaft for the 1st to 4th gears in the -direction of the arrow-. l  The input shaft, secondary shaft and crown teeth should all be engaged –  Using the help of the second mechanic, press the shafts and the differential into their seats.

–  Secure support bridge -U-40007- for input shaft to clutch housing.   Note For clarity of illustration, clutch housing is shown turned 180°. –  Screw the centre screw of the -U-40007-retaining tool until the drive shaft partially contact the tool.

Grooved ball bearing for input shaft will fit into gearbox housing in one position only. The ball bearing and its mount have a flattened location. l  When flattened locations -A- and -B- are present, washers must not be mounted on the top nor on the bottom of the ball bearing → Chapter. l  The flattened area -A- of the ball bearing must correspond with the flattening of the mount -B- that is in the gearbox casing for this purpose. –  Mark the flattened area in colour. –  Extend the marking up to the top side of the ball bearing and the bearing housing in the gearbox casing (⇒ following Fig.). –  Using the hot air blower -SAT 1416-, heat the gearbox casing, in the area of the input shaft groove ball bearing mount for approx. 10 minutes until a temperature of about 100 °C.   Note t  Heating is necessary to ensure that grooved ball bearing is not damaged when installing gearbox housing. t  Apply the sealing compound equally on the surface of the clutch housing to be sealed → Spare parts catalogue.

t  Align the marking of the ball bearing -A- to the gearbox casing -B- and mount the gearbox casing above this.

–  Fit the gearbox housing and tighten the new screws -A-, -B- and -C- with the specified tightening torque. Allocation of bolts: A  -  Bolt with captive washer. B  -  Bolt without washer. C  -  Bolt with captive washer. –  Fit the circlip for the grooved ball bearing of the input shaft. –  Extract the counterhold -U-40007 -.

–  If the insertion sleeve for the selection shaft was removed it must be fitted using the tool -T20188 - to the limit of the tool with the gearbox housing. –  Rotate the gearbox on the assembly frame so that the opening for the selection shaft is upwards.

–  Fit the selection shaft -1- into the lower allotment -2- and onto the prongs -3-.   Note For better clarity, sealing cover is removed in illustration.

–  Press the selection rod -1- against the retention sleeve -2-, -arrow-, and face it under the operation finger -3-, of the prongs, to the limit. l  While doing this, the gear mechanism cover -4- should remain parallel to the surface where the gearbox housing is bolted l  The selection shaft should be easily moved upwards and downwards (selection movement)   Note If selector shaft cover is tilted relative to bolting surface, selector shaft is not inserted in lower bearing.

–  Tighten bolts -3- for selector shaft cover -4-. Tightening torque → Item –  Attach fastening screw -2- Tightening torque → Item, for this, the anchor pin -arrow- for the selection shaft lock must be in rest position. –  Install the reversing light switch -1-. Tightening torque → Item –  Drive in input shaft seal → Chapter. –  Fit the clutch slave cylinder with the release collar. → Item –  Successively select all gears.

Cover plate identification -I- = sheet metal cover plate; secured with circlip -A- -II- = plastic cover plate; without circlip

Allocation

Receptacle for cover plate	Sealing cap	Drive in
-Arrow A- = vertically	Made of sheet metal	→ Fig.
-Arrow B- = diagonal	Made of plastic	→ Fig.

Sheet metal cover plate –  Drive sealing cap into gearbox housing onto stop.

–  Secure sealing cover plate with retaining ring -A-.

Plastic cover plate –  Drive sealing cap into gearbox housing onto stop. Continuation for all vehicles l  Always observe cover plate allocation → Fig.. l  Leak may occur when installed incorrectly l  Cover plate → Electronic parts catalogue „ETKA“ –  Drive in input shaft seal → Chapter. –  Fit the clutch slave cylinder with the release collar. → Item –  Successively select all gears.

–  Insert the sealing cover using the pressure tool -T10042 - as far as possible in the gearbox housing. Mount the bevel box onto the manual gearbox as follows: –  Displace the bevelled gear until it rests against the manual gearbox, then connect the teething of the drive shaft / bevelled gear centred with the differential. –  Also align the splines of the flange shaft (right-side) and the differential pinion, if necessary also turn the flange shaft. –  When the position is correct, the cogs and the centring slide the bevelled gear up to the end in the direction of the manual gearbox.   Note Do not use the securing bolts to pull the bevel box onto the gearbox. This could cause the bevel box to tilt and the securing eyes may break off. –  Install the bevelled gear → Chapter. –  Screw on the conical bolt of the right flange shaft using the "1/4" threading die mount" -T20203A-. –  Install gearbox → Chapter.