SEAT Workshop Service and Repair Manuals

Removing –  Drain gearbox oil.

–  Place the gearbox on column -AR-2203 A- and secure in the holes numbered 1 and 8 of the support.

–  Remove the clutch pushrod from the input shaft -A-.

–  Fit tool -U-40007- for holding input shaft, securing it to the clutch housing with two bolts. –  Bolt the shaft of tool -U-40007- until it rests on the input shaft and lock it with the locknut.

–  Unbolt the protective cover from the bodywork -arrows-.

–  Remove reversing light switch -arrow 2- and the locking bolt -arrow 1- for the gear selector shaft -A-. –  Remove the control -B- from the speedometer.

–  Unscrew the the gear selector shaft cap with tool -U-20020- and remove with the compression spring. –  Set the gear selector shaft in neutral and remove it from the gearbox casing.

–  Remove the Torx bolt that secures the reverse gear -arrow-.

–  Remove both articulation flanges. –  Remove the articulation flanges with the pressure springs, thrust washers and conical rings.

–  Select 5th gear -arrow 1-. –  Select reverse gear -arrow 2-, pushing the front connecting mouth down.

–  Unscrew the syncromesh bolt -arrow- with the XZN 12 mm spanner, from tool -U-40020-.

–  Release the lock tab for the connection pipe, by levering both ends at the same time.

–  Release the connection tube from the fork by unscrewing it to the left with tool -U-40200/8-.   Note! Do not remove the control rod from the connection tube.

–  Remove the complete syncromesh together with the sliding sleeve and the 5th gear fork, pushing a little if necessary, with two levers, but taking care not to damage the sealing surfaces. –  Make sure there is a thrust washer for the gear below the syncromesh.

–  Remove the safety ring and thrust washer -A- for the 5th gear.

–  Remove 5th gear with tool -U-40100/1- if necessary.

–  Remove the retaining plate (support for input shaft ball bearings) -arrows-. –  Remove the bolts that secure the gearbox casing to the clutch housing.

–  Fit bolt -A- of the input shaft syncromesh -B- as far as it will go using XZN 12 mm spanner, from tool -U-40020-

–  Remove the gearbox casing with tool -U-40200/7A-.   Note! Align the bolt of tool -U-40200/7A- with the input shaft.

–  Remove the control rod -A- from the clutch housing orifice and remove the gearbox forks -B- tilting them. –  Remove the safety ring for the 4th gear of the layshaft.

–  Remove the 4th gear with tool -U-40100/1-. Tilt the input shaft slighly to remove the gear.

–  Remove the input shaft -A- complete.   Note! The reverse gear -B- must not be engaged.

–  Remove the safety ring -A- on the 3rd gear. –  Remove the safety ring -A-, if fitted.

–  Remove the sliding 2nd gear to remove the 3rd gear with tool -U-40100/1-. –  Remove the syncromesh and the needle roller bearing. –  Remove the reverse gear with the aid of the threaded bolt and a plastic hammer. –  Remove the reverse gear from coupling lever.

–  Remove the syncromesh sleeve assembly and the 1st gear together with the 2nd gear needle bearing bush with tool -U-40100/1-.

–  Remove the bolts from the bearing housing -arrows- and remove the layshaft without forgetting the thrust washer -1-. –  Remove the diferential.