SEAT Workshop Service and Repair Manuals

Clutch casing: repair

Assembly chart

1 -	Grub screw for the selecting bar, 40 Nm

2 -	Guide collar

q

2 units

3 -	Outer ring, tapered roller bearing

q	For primary shaft

q	Dismounting and assembly → Fig.

4 -	Adjusting washer

q	For primary shaft

q	Calculate the thickness → Chapter

5 -	Clutch release lever

q	Dismounting and assembly → Chapter

6 -	Screw plug with closing cover

7 -

Vent pipe

8 -	Clutch casing

q	If being replaced, see adjustment chart → Chapter

q	Adjust the selector finger and drag link.

9 -	Primary shaft retainer

q	Dismounting → Fig.

q	Assembly → Fig.

10 -	Guide collar

11 -	Securing screw for the guide collar, 20 Nm

12 -	Clutch release bearing

q	Dismounting and assembly → Chapter

13 -	Bearing bush for the starter motor

q	Dismounting → Fig.

q	Assembly → Fig.

14 -	Guide lug for speedometer mechanism shaft

15 -	Speedometer mechanism shaft

16 -	Right coupled flange retainer

q	Dismounting → Fig.

q	Assembly → Fig.

q	Replacement with the gearbox mounted in the vehicle → Chapter onwards

17 -	Plate collar

q	For coupled flange retainer → Item

q	Dismounting → Fig.

q	Assembly → Fig.

18 -	Gear selection lever oil seal

q	Remove carefully using a screwdriver as a lever → Fig.

q	Assembly → Fig.

q	Can be replaced with the gearbox mounted in the vehicle

19 -	Front bearing bush for the selector shaft

q	Dismounting → Fig.

q	Assembly → Fig.

20 -	Selector shaft

q	Assembly position: the bevel edge -arrow- must face the guide collar → Item

q	Lubricate the sliding surfaces with molybdenum sulphide (MoS2)-based grease.

q	If replacing, adjust the selector finger and the guide collar → Chapter

21 -	Guide collar

q	Adjustment → Chapter

22 -	Securing screw for the guide collar, 25 Nm

23 -	Adjusting washer for the differential

q	Calculate the thickness → Chapter

24 -	Outer ring for the differential tapered roller bearing

q	Dismounting and assembly → Chapter

q	If replacing, adjust the differential → Chapter

25 -	Adjusting washer for the secondary shaft

q	Calculate the thickness → Chapter

26 -	Outer ring for the secondary shaft tapered roller bearing

q	Dismounting and assembly → Fig.

27 -	Rear bearing bush for the selector shaft

q	Dismounting → Fig.

q	Assembly → Fig.

Special tools and workshop equipment required

t	Impact retainer extractor -U-10080-

t	Primary shaft retainer assembly tool -U-20017-

t	Notched socket set XZN -U-40020-

t	Tool for attaching the starter motor bush -U-40027-

t	Taps for Ø11 and Ø14 with percussor -U-40087-

t	Replacement parts extractor case -U-40100-

t	Tool for attaching the drive train-differential retainer and bush -U-40091-

t	Tool for dismounting/assembling the selector shaft bush and retainer -U-40053-

t	Replacement parts case -U-40200-

t	Tool for dismounting/assembling the selector shaft bearing bush -U-40204-

Removing the retainer on the primary shaft –  Remove the clutch release bearing. –  Remove the screws securing the guide collar, together with the guide collar, using tool -U-40020-. –  Take out the retainer using tool -U-10080-.

Attaching the primary shaft retainer –  Lubricate the retainer well and slide it carefully on the primary shaft. –  Insert the retainer using tool -U-20017-.

Dismounting the bearing bush for the starter motor –  Put the threaded tap of tool -U-40087- on the bush and screw right in. –  Activate the percussor until the bush comes out.

Assembling the bearing bush for the starter motor –  Lubricate the bearing bush with oil. –  Insert it in the clutch casing with tool -U-40027- side B until it sits right in.

Dismounting the coupled flange retainer –  Use tool -U-40100/2-. –  Activate the retainer until the retainer comes out.

Assembling the coupled flange retainer –  Lubricate the retainer with oil. –  Attach the retainer using tool -U-40091-.   Note! Tool -U-40091- has different diameters for inserting various retainers. Choose the most appropriate one.

Dismounting the plate collar for the coupled flange retainer –  Carefully pry out the collar using a screwdriver. t  If the collar is worn or damaged, it must be replaced.

Assembling the plate collar for the coupled flange retainer –  Coat the contact surface of the collar with sealing paste. –  Fit the collar using tool -U-40091-.   Note! Tool -U-40091- has different diameters for inserting various retainers. Choose the most appropriate one.

Removing the gear selection lever oil seal –  Engage a gear that will result in the gear selector shaft being moved outwards. –  Cover the gear selector shaft with thin insulating tape to avoid damage when removing the seal. –  Move the gear selector shaft fully inwards. –  Carefully make a hole in the centre of the seal -arrow- with a small screwdriver. –  Remove the seal, using a larger screwdriver as a lever. –  Engage a gear that involves moving the gear selector outwards, remove the insulating tape and ensure that the shaft is not damaged.

Assembling the selector shaft retainer –  Lubricate well the retainer. –  Insert the retainer using tool -U-40053-.

Dismounting the front selector shaft bearing bush Before dismounting and assembling the bearing bush, the selector shaft retainer and selector shaft must be removed. –  Take out the bearing bush with tool -U-40204- (side A) and tool -U-40200/10-.

Assembling the front selector shaft bearing bush –  Insert the bearing bush with tool -U-40204- (side B) and tool -U-40200/10-. t  The bearing bush must be inserted 10 mm below the surface of the clutch casing.

Dismounting the rear selector shaft bearing bush –  Take out the bearing bush with tool -U-40204- (side A) and tool -U-40200/10-.

Assembling the rear selector shaft bearing bush –  Insert the bearing bush with tool -U-40204- (side A) and tool -U-40200/10-. t  The bearing bush must be inserted flush with the rear part of the housing vent.