SEAT Workshop Service and Repair Manuals

Removal

–  Fit the gearbox to column -AR-2203A-. Use drills No. 4 and 5. –  Drain gearbox oil. Unscrew oil drain plug from gearbox.

–  Remove clutch release bearing -B- and release fork -A-. –  Remove guide bush -C-.   Note! Remove the guide bush securing bolts with the correct diameter of tool -U-40020-.

–  Remove the right and left flanged shafts. –  Remove the flanged shafts with pressure springs, thrust washers and conical rings.

–  Unscrew the gearbox casing cover and remove the gasket. –  Bolt the connection finger or tool -U-40203- to the connection shaft. –  Select 5th gear.

–  Loosen the counter nut -arrow 1- located under the 5th gear connection fork. –  Remove the dome headed bolt -arrow 2- and remove the connection fork with the 5th gear sliding sleeve.

–  Fit the sliding sleeve of the 5th gear on the syncromesh body. –  Remove bolt -A- for the 5th gear. To lock it, select 5th gear by hand by pushing the slider -arrow 1- and select 2nd gear with the selector -arrows 2- and -3-. –  After selecting the gears, the input and layshafts are locked, the body of the syncromesh and the gear cannot move and thus it is possible to loosen the bolt. –  Remove 5th gear sleeve and remove 2nd gear.

–  Remove safety ring -arrow- from the syncromesh body of the 5th gear.   Note! Use tool -A-81124- to remove the safety ring.

–  Remove the syncromesh body and the sliding 5th gear with tool -U-40100/1-. –  Remove the needle bearing for sliding 5th gear.

–  Remove 5th gear with tool -U-40100/1-. The 5th gear bearing bush will only be removed if the needle roller bearing needs to be replaced, proceed as follows: –  Heat the bearing bush to about 100 °C with the electric blower -SAT 1416-.

–  Remove the needle bearing bush. Use tool -T20022- with claws -T20022/44-. –  Remove the thrust washer located under the needle bearing bush.

–  Separate the clip -arrow- from the 5th gear control rod. Compress with pliers and pull in the direction of the layshaft.

–  Separate the speedometer sender -arrow-.

–  Remove the bolts securing the clutch housing from the gearbox casing. –  Separate both casings by tapping with a plastic hammer. No not damage the contact surfaces. –  Remove the differential from the gearbox casing.

–  Remove the connection shaft cap -A- with tools -U-40200/25- and -U-40200/21-.

–  Remove the connection shaft with a drift.

–  Remove the spring -arrow- between the selector finger -A- and the gear console -B-. –  Remove the selector finger -A-.

–  Remove the bolt -arrow- and remove the gear console and the bush.

–  Remove the reversing light switch -1- and the bolts -2-, -3- and -4-.

–  Remove the control rod for the 5th gear -1- and the reverse gear control rod -2- together with the coupling rod -3-.

–  Remove the reverse gear shaft from the gearbox casing from the bottom; if necessary use tools -U-40200/3- and -U-40200/10-.

–  Remove input shaft -5-, control rod and fork for 3rd and 4th gears -6-, the reverse gear shaft -1-, the reverse gear -2-, as well as the secondary shaft -4- and the control rod with fork for the 1st and 2nd gears -3-.