SEAT Workshop Service and Repair Manuals

Removing and installing input shaft cover Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter Special tools and workshop equipment required

t  Seal extractor -T40014-

t  pressure tool -T40099- t  Ice spray t  Wear protective gloves! t  Protective glasses

Detaching l  Input shaft is removed → Chapter –  Pull out oil pipe -arrow- upwards so as to avoid damage.

–  Check all 8 bolts -arrows- of stand -T40099-. l  Bolts should have been screwed in flush to 25 Nm → Assembly instructions for thrust piece T40099.

–  Place input shaft in stand -T40099-. –  Turn in the oil seal extractor -T40014- into the radial shaft seal by hand until the tool engages in the radial shaft seal. Then tighten tool using an open-ended spanner. –  Screwing in the rear bolt -arrow- will allow you to pull the oil seal out a little. –  Then tighten again using open-end spanner so that oil seal extractor -T40014- engages securely in the radial shaft seal again and pull out the radial shaft seal by screwing in the bolt. –  Repeat procedure until oil seal is pulled out all the way.

–  Remove retaining ring from input shaft cover -A-. –  Measure and note down thickness of retaining ring once removed.   Note When installing ball bearing, replace circlip with a new one of the same thickness.

–  Clean sealing surface -arrow- of cover.

WARNING Risk of burns Wear protective gloves and safety goggles! –  Cool the hollow shaft -1- in the mount -arrow 2- of the bearing „A“-item 2- (ball bearing for the input shaft) through the opening -arrow 1- e.g. using ice spray.   Note t  The illustration shows a sectional view of the shaft. t  The shaft has to be cooled so that cover and bearing „A“-item 2- (ball bearing for input shaft) can be pressed off more easily without damage.

–  Clean surface of stand -T40099-. –  Place input shaft in stand -T40099-. l  Sealing surface of input shaft should be seated flush on the thrust piece. l  Make sure there are no objects such as cable ties or dirt between the sealing surface of the input shaft and the surface of the stand -T40099-.   Caution Metal particles or dirt will damage the sealing surface of the cover when pressing off and the cover will then have to be renewed. –  In addition, cool the shaft from the outside -arrow- e.g. with ice spray.   Note The shaft has to be cooled so that cover and bearing „A“ (ball bearing for gearbox input shaft) can be pressed off more easily without damage. –  Position input shaft together with stand -T40099- on pressure plate of hydraulic press.   Note The stand -T40099- must rest as firmly as possible on the hydraulic press.

–  Hold shaft from underneath and at the same time use hydraulic press to press shaft out of cover.

–  Set down input shaft on assembly tool -T10219/1-.   Note Screwdriver and arrows can be disregarded.

Installing –  Renew bearing „A“ (ball bearing for gearbox input shaft) in input shaft cover → Chapter. –  Place input shaft cover on input shaft and press on as far as possible by hand.

–  Place input shaft -B- on thrust plate -VW 401-.   Caution Take care to keep the input shaft straight and aligned centrally when positioning it beneath the press tool of the hydraulic press, as the input shaft may otherwise tilt to one side when pressure is applied to the cover. –  Drive the cover -A- into the input shaft as far as it will go using the hydraulic press and the press tool -VW 416B-.

Fitting retaining ring for input shaft cover –  Replace retaining ring -A- with a new one of the same thickness when installing.   Note Check that circlip is seated properly.

Installing oil pipe –  Assess wear on gearbox components → Chapter. –  Renew O-ring -2- on oil pipe. l  The oil pipe is pressed into the input shaft with the O-ring -2- first. l  You should feel oil pipe engage. Rotor vanes -arrow A- on oil pipe should be completely inside input shaft.

–  Press oil pipe -arrow- down into input shaft as far as stop. l  With oil pipe fully inserted, distance from end of oil pipe to input shaft should be approx. 11.5 mm. If the distance is less, the oil pipe may be damaged (the end could have broken off if the oil pipe was pushed in too far). If the distance is larger, the oil pipe is not pushed in far enough.   Caution t  Do not put down input shaft on the protruding oil pipe -arrow-, as oil pipe would then become damaged. t  A damaged oil pipe will cause drive-away problems or complete gearbox failure.