SEAT Workshop Service and Repair Manuals

Gearbox casing and clutch casing: repair

Assembly chart

1 -	Gearbox casing

q	In the event of replacement, see adjustment chart → Chapter

2 -	Secondary shaft needle bearing

q	For secondary shaft

q	Dismount → Fig.

q	Assemble and fix into place → Fig.

3 -	Lid for control of oil level.25 Nm

q	Without magnet

4 -	Adjustment washer for main shaft

q	In the event of replacement, see adjustment chart → Anchor

5 -	Outer track, tapered roller bearing for main shaft

q	Dismount and assemble → Chapter

q	In the event of replacement, see adjustment chart → Chapter

6 -	Outer track, tapered roller bearing for secondary shaft

q	Dismount and assemble → Chapter

q	In the event of replacement, see adjustment chart → Chapter

7 -	Adjustment washer for secondary shaft

q	In the event of replacement, see adjustment chart → Anchor

8 -	Outer track, tapered roller bearing for main shaft

q	Dismount and assemble → Chapter

q	In the event of replacement, see adjustment chart → Chapter

9 -	Axial/radial needle bearing for reverse gear axle

q	Dismount and assemble → Chapter

10 -	Centring bushes

q

2 units

11 -	Bush-bearing for the start motor

q	Remove → Fig.

q	Assemble → Fig.

q	It may be replaced with the gearbox mounted

12 -	Clutch casing

In the event of replacement, see adjustment chart → Chapter

13 -	Guide sleeve

q	With retainer for main shaft and vulcanised O-ring seal

q	Dismount → Fig.

q	Assemble → Fig.

q	In order to replace the retainer for the main shaft it is necessary that the guide sleeve be dismounted.

q	Replace the guide sleeve if the O-ring seal is damaged.

14 -	Bolt for attaching the guide sleeve .20 Nm

q	Self-blocking

q	Always replace

q	Tightening torque: 20 Nm

15 -	Retainer for right coupling flange

q	Replacement with the gearbox mounted in the vehicle → Chapter

16 -	Plate sleeve

q	For coupling flange retainer → Item

q	Dismount → Fig.

q	Assemble → Fig.

17 -	Shaft for operating speedometer 30 Nm

18 -	Top for emptying oil. 25 Nm

q	Without a magnet

19 -	Outer track for the tapered roller bearing in the differential

q	Dismount and assemble → Chapter

q	In the event of replacement, adjust the differential → Chapter

20 -

Magnet

q	It is held between the casings for the gearbox and the clutch

21 -	Outer track for the tapered roller bearing in the differential

q	Dismount and assemble → Chapter

q	In the event of replacement, adjust the differential → Chapter

22 -	Adjustment washer for differential

q	Finding the thickness →

23 -	Retainer for left flange

q	Replacement with the gearbox mounted in the vehicle → Chapter

Special tools and workshop equipment required

t	Gearbox repairs case -U-40200-

t	Gearbox repairs case -U-40300-

t	Taps for Ø 11 and Ø 14 with plunger -U-40087-

t	Tool for assembling starter sleeve -U-40027-

t	Support column for gearbox-differential -Ar-2203A-

Dismounting the needle bearing for the secondary shaft –  Dismount the needle bearing from the gearbox casing using tool -U-40200/10- and tool -U-40300/1-.

Assembling and fitting the needle bearing for the secondary shaft –  Assemble the needle bearing in the gearbox casing using tool -U-40200/10- and the tool -U-40300/12-. –  Fit the bearing by making three marks with a marking hammer set out with 120º between each other.

Dismount the retainer for the main shaft in the guide sleeve –  Dismount the retainer for the main shaft in the guide sleeve by carrying out the following steps: –  Place the guide sleeve over tool -U-40300/9-. –  Dismount the retainer for the main shaft in the guide sleeve using tool -U-40300/2- with side A facing towards the sleeve and tool -U-40200/10-.

Assemble the retainer for the main shaft in the guide sleeve –  Assemble the retainer for the main shaft in the guide sleeve, carrying out the following steps: –  Place the guide sleeve over the tool -U-40300/9-. –  Assemble the retainer for the main shaft in the guide sleeve using tool -U-40300/2- with side B facing towards the sleeve and tool -U-40200/10-.

Dismounting the sleeve-bearing for the start-up motor –  Place the top of tool -U-40087- on the sleeve and tighten it right to the end. –  Work the initiator until extracting the sleeve.

Assembling the sleeve-bearing for the start-up motor –  Lubricate the sleeve-bearing with oil. –  Fit it into the clutch casing, with tool -U-40027- side B, right up to the top.

Dismounting the plate sleeve for the coupling flange retainer –  Remove the sleeve by levering out carefully with a screwdriver. t  If the sleeve is damaged or has defects, it must be replaced.

Assembling the plate sleeve for the coupling flange retainer –  Impregnate the contact surface of the sleeve with sealing paste. –  Fit in the sleeve using tool -U-40200/13- with the trimming of the tool facing towards the sleeve and tool -U-40200/10-.