SEAT Workshop Service and Repair Manuals

Dismounting

–  Attach the gearbox onto the column -Ar-2203 A-. Use drill holes Nos. 1 and 6. –  Empty the gearbox oil. Unscrew the top off for emptying the gearbox oil. –  Dismount the release bearing and the release fork. –  Remove the bolts for attaching the guide sleeve. t  Remove the bolts attaching the guide sleeve with a suitable diameter spanner from tool -U-40200-. t  Remove the guide sleeve, with a vulcanised O-ring seal.

–  Unscrew the cover for the gearbox casing -arrow- and remove the seal.

–  Remove the bolts -arrow- and take out the fork for the 5th gear.   Note! Before lifting out the movable one, remove the spring and the block body. Next put the movable one back in, without the fork, over the body of the synchroniser.

–  In order to be able to loosen the two bolts -A- that attach the 5th gear pinion and the synchroniser, perform the following steps: Push the movable sleeve for the 5th gear downwards -arrow 1-. Also connect the 1st gear by pushing the selector lever inwards -arrow 2- and turning -arrow 3-. –  The primary and secondary shafts remain blocked since two gears are connected; the synchronising bushing and the 5th gear pinion do not turn. Unscrew the bolts -A- and take them out. –  Remove the movable sleeve for the 5th gear.

–  Dismount the synchronising bushing and the 5th gear pinion. Use the tool -U-40100/1-. –  Remove the needle bearing for the 5th gear pinion.

–  Remove the 5th gear pinion. Use the tool -U-40100/1-.   Note! t  In order to remove the 5th gear pinion, first heat to about 80 º C using the electrical blower -SAT 1416-. t  During the removal work, check that the legs of the extraction device do not bend outwards. Check that the 5th gear pinion is not damaged.

–  Remove the right-hand and left-hand coupling flanges. –  Remove the coupling flanges together with the springs, the thrust washers and the tapered rings.

–  Dismount the two bolts -arrows- for supporting the reverse gear axle.

–  Put the gear selector axle into neutral. Extract the attachment bolts -arrow- and remove the gear selector axle from the gearbox casing.

–  Dismount the close cover -A- and the support bolts -B- from the lower part of the gearbox, first extracting the bolts -1- and -2-.

–  Dismount the support bolts -A- from the upper part of the gearbox and the bolts -B- for attaching the gearbox casing to the clutch casing.

–  Dismount the bolts -A- for attaching the clutch casing to the gearbox casing.   Note! Do not remove the nuts -B- for attaching the secondary shaft.

–  Separate the gearbox casing by hitting lightly with a plastic hammer. Do not damage the surfaces for fitting them together.

–  Extract the forks -A- together with the connection guides. –  Remove the bolt -B- and extract the fork for the reverse gear.

–  Extract the nuts for attaching the secondary shaft -B-.   Note! Place the gearbox axles in an upright position before completing the removal of all the bolts -B-.

–  Extract from the clutch casing, in the following order, the reverse gear axle -A-, the main shaft -B- and the secondary shaft -C-. –  Withdraw the differential unit from the clutch casing.