SEAT Workshop Service and Repair Manuals

Installation   Note If the allotment for the bearing bush of the gearbox casing is loose then it must always be replaced → Item.   WARNING Wear protective gloves! –  Allow the bearing allotment to cool to approx. 100 °C, –  Insert the bearing bush allotment along with the rigid radial bearing.

–  Press on the sleeve -A- for the needle bearing of the 5th gear

–  Once assembled, fit the input shaft -2- and the secondary shaft -1- with the bearing bush allotment for the rigid radial bearing on the tool -T10085 -. –  Screw in the guide sleeve -T10079- on the threaded (reverse gear attachment) pin -arrow-. –  Insert selector mechanism (selector forks) -4- in the shaft locking collars. –  Place the shaft -3- together with the reverse gear sprocket → Item.

–  Fit all components together in the gearbox casing. For this purpose, insert the guide sleeve - T10079- over the opening for fixing the gear selector mechanism on the gearbox into the gearbox casing. –  Unscrew the guide sleeve -T10079 -.

Before adapting, the following must be checked. t  The selector forks must engage in the locking collar correctly. t  Dimension -a- of the input shaft splines.   Note t  The input shafts of the different gearboxes have different lengths as dimension -a- is different. t  In order to allow an equal fit between the secondary and input shafts, a washer -T10083/1- (3 mm thick) has to be mounted on the input shaft. t  For this person, dimension -a- of the secondary shaft splines has to be measured.

Dimension -a- = 30.6 mm

Place the washer -T10083/1- on the input shaft → Fig.

Place the washer -T10083/1- onto the input shaft and – carefully – press in the allotment together with the input and secondary shafts to the end.

–  Carefully press in bearing mounting together with input shaft and output shaft to stop. –  Secure the bearing bush allotment with a hand tightened bolt.

–  Screw in the bolt -A- securing the reverse gear pinion shaft → Item. –  Fit the bearing bush pins -B- in the lower part of the gearbox → Item.   Note -Arrow- can be disregarded.

–  Screw in the reverse light switch -F4---C → Item. –  Align the gear operation mechanism and fit the socket pins -B- for the upper part of the gearbox → Item.   Note Ignore positions -A and arrows-. –  Set selector plates in neutral position. –  Clean the sealing surfaces; these must be clear of grease and oil. l  Apply sealing compound → Electronic spare parts catalogue „ETKA“.

Fit the selection shaft –  Fit the selection shaft along with the cover of the gear mechanism -A-. Then, tighten bolts -arrows- → Item.

–  Using new bolts -A- → Item, tighten bearing mounting for input and output shafts.   Note Tighten the bolts to the corresponding torque, → Item in steps and diagonally, beginning in the centre. –  Tighten the nut with the collar -B- securing the gear operation mechanism (prongs). Tightening torque → Item –  Check that all the gears can be connected without problems. –  Install differential. –  Clean the sealing surfaces; these must be clear of grease and oil. –  Apply sealing compound → Electronic spare parts catalogue „ETKA“ evenly to sealing surface. –  Rotate the input shaft by hand when positioning the housing so that the bearing enters its seat easily.

–  Tighten the bolts -arrow- for the gearbox housing diagonally and in steps → Item. –  Turn gearbox in support bracket so that gearbox housing is upwards.

–  Drive on 5th gear wheel. l  Fitting position for 5th gear pinion the collar -arrow-should be orientated towards the gearbox casing cover

–  Fit the following components one after the other: 1  -  Needle roller bearing for 5th speed selector gear 2  -  5th gear mobile pinion 3  -  Synchromesh ring of 5th gear: 4  -  Synchronising hub with locking collar and check ring for 5th gear

–  Insert the selector fork for 5th gear -2- and push the´bearing bolt -1- to the limit in -the direction of the arrow-. –  Decide the safety ring -arrow- of greatest thickness that can be fitted in the gap of the primary shaft -3- and the secondary shaft -4-. Available retaining rings → Electronic spare parts catalogue „ETKA“

Thickness (mm)
2,00	2,10
2,20

–  Fit the gearbox casing cover → Item.

–  Seat using pressure on both flanged shafts with compression springs, thrust washers and conical rings to the gearbox casing and tighten. –  Fit the clutch release lever with clutch release collar and guide sleeve → Chapter. –  Replace gearbox oil and check fill level → Chapter.