SEAT Workshop Service and Repair Manuals

Dismantling –  Remove gearbox. → Chapter –  Secure the gearbox to installation stand. → Chapter –  Drain the gearbox oil. → Chapter –  Remove clutch release lever and collar. → Chapter –  Disassemble the guide sleeve. → Chapter –  Remove the cover of the 5th and 6th gears from the gearbox housing. (If necessary, carefully lever on the reinforcement located on the outer circumference changing sides so that the surface of the seal is not damaged).

–  Remove 5th / 6th gear selector fork and locking collar as follows: –  Engage the 5th gear, following the actions of the arrows -1- and -2- –  Remove the selector jaw for 5th / 6th gear, bolt -A-. –  Then, remove the bolts -B- from the socket pins. –  Extract the socket pins. –  Remove the selector forks for 5th / 6th gear.

Remove the 6th gear –  Unscrew the bolts -A- of the input and secondary shaft; to do this the 5th gear -arrow 1- and the 1st gear -arrows 2 and 3- must be engaged. –  Both the input shaft and the secondary shaft are locked when both gears are engaged. The bolts can now be loosened -A-.   Note If the shafts are not to be replaced, clean both of the screw holes using a threading male to eliminate the traces of fixing agent.

–  Remove the two bolts -arrows- which support the reverse gear shaft.

–  Now remove 3rd bolt -arrow- for reverse shaft support.

–  Place the gear selector shaft in neutral. Remove the attachment bolts -arrows- and remove the gear selector rod from the gearbox housing.

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

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

–  Remove the bolts -A- which secure the clutch housing to the gearbox casing.   Note t  Do not remove the nuts -B- for fitting the secondary shaft. t  Position the gearbox shafts vertically before removing all nuts -B-.

–  Remove both flange shafts. –  Remove the flanged shafts with the pressure springs, the thrust washers and the conical rings.

Pull off following components together with gearbox housing: t  Synchro-hub for 5th/6th gears t  Gear wheel for 6th gear t  5th gear pinion l  Both grips -T10408/3- must be secured on gear wheel for 5th gear. l  The grips must always be positioned above the two housing ribs, which are located opposite each other -arrows-.   Note t  There is a needle bearing beneath the gear wheel for 5th gear. t  Secure the grips so that the bearing does not come in contact with the gear wheel for 5th gear when the gearbox housing is pulled off.

Use puller plate -T10408- in conjunction with following special tools: t  Thrust blocks -T10408/2- t  Tabs -T10408/3- t  Puller Kukko 18/1 –  Screw puller plate -T10408- firmly into threaded holes for gearbox housing cover. A -  Hexagon bolts M7 x 35 with washers Tightening torque: 18 Nm –  Place thrust pieces -T10408/2- on shafts.

–  Install pullers Kukko 18/1-A-. –  Pull off 5th and 6th gear synchro-hub, gear wheel for 6th gear, gear wheel for 5th gear and gearbox housing by alternately tightening spindles -A- approx. 1 2 turn. –  If necessary, heat 5th and 6th gear wheels slightly using hot air blower -V.A.G 1416-, for example.

–  Remove the nuts -B- for fitting the secondary shaft. The bolts -A- have already been removed.

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

Gearbox with selector lever for reverse gear -arrow- –  Screw off the gear selection mechanism of the reverse gear -B- (⇒ previous illustration).

–  Remove clutch casing by order, reverse gear shaft -A-, input shaft -B- and secondary shaft -C-.

Gearbox with locking collar for reverse gear -arrow-

–  Remove the output shaft -1-, the input shaft -2- and the inverter shaft -3- together from the clutch housing. Continued for all vehicles –  Remove differential.