SEAT Workshop Service and Repair Manuals

Gearbox: remove

–  Secure the gearbox to installation stand. –  Place drip tray -V.A.G 1306- under gearbox. –  Drain gear oil.

–  Remove clutch release lever -A- together with release bearing. –  Remove guide sleeve -B- –  Remove dished spring -C-. –  Then remove circlip -D- in front of ball bearing for input shaft.   Note If the input shaft or gearbox housing is not to be renewed, note the thickness of the circlip.

–  Pull the ball bearing for input shaft out of gearbox housing.

–  Remove the circlip -arrow- behind the ball bearing for input shaft.   Note If the input shaft or gearbox housing is not to be renewed, note the thickness of the circlip.

–  Remove bolts -arrows- and take off selector shaft cover -A-.

–  Unscrew the two locking bolts -1- for selector shaft. l  Make sure that no gear has been engaged. –  Push selector shaft -2- into gearbox as far as it will go, simultaneously removing pin -3-. –  Pull out selector shaft.

–  Move two selector rods -arrow A- and -arrow B- to lock input shaft by selecting two gears (e.g. reverse gear and 1st gear).

–  Unscrew securing bolts for gearbox cover -arrows-.

–  Carefully pull off gearbox cover -A- towards rear. The bearing housing -B- remains fitted to the gearbox housing -C-.

–  Secure bearing housing to gearbox housing -arrows- with two bolts M8 (length approx. 70 mm) and washers. –  Tighten these 2 bolts -arrows- to max. 5 Nm. –  Detach oil collector -A-.

–  Check that the 2 gears are still engaged and then unscrew and remove the multi-point socket head bolt -1- for input shaft.

–  Detach 6th speed selector gear with inner race for roller bearing and thrust washer. A  -  Two-arm puller, e.g. -Kukko 20/10-   Note Check the gear teeth on the selector gears and gear wheels for damage after pulling them off. –  Remove synchro-ring and needle bearing for 6th speed selector gear.

–  Pull off 6th gear wheel A  -  Two-arm puller, e.g. -Kukko 20/10- –  Remove spacer sleeve from output shaft.

–  Pull out pin with clip -A- for securing selector fork for 5th and 6th gear from selector rod -B-. l  Using a felt pen, for example, mark the mounting position of the sliding sleeve of the synchromesh hub -arrow-. –  Move selector fork -C- downwards and detach with locking collar -D-.

–  Pull off 5th speed selector gear together with needle bearing inner race for 6th gear and synchronising hub for 5th and 6th gear. A  -  Two-arm puller, e.g. -Kukko 20/10- with puller hook, length 200 mm   Note t  Counter-hold two-arm puller using e.g. open end spanner -B-. t  If the needle bearing inner race for 6th gear is in contact with press tool - VW 433-, insert locking pin -2064- into hole in input shaft to pull off the components all the way. t  Never force the extraction of the inside rings / sleeves. If necessary, clean and heat with a maximum temperature of 130°C.

–  Pull off 4th and 5th gear wheels together. A  -  Puller, e.g. -Kukko 18/2-   Note Counter-hold puller-A- using e.g. gearbox bracket -2004-.

–  Pull off 4th speed selector gear with needle bearing inner race for 5th gear and thrust washer. A  -  Two-arm puller, e.g. -Kukko 20/10- with puller hook, length 200 mm –  Counter-hold two-arm puller using e.g. open end spanner -B-. –  Remove synchro-ring and needle bearing for 4th speed selector gear.

–  Pull pin with clip -A- securing selector fork for 3rd and 4th gear out from selector rod -B-. l  Using a felt pen, for example, mark the mounting position of the sliding sleeve of the synchromesh hub -arrow-. –  Detach selector fork -C- with locking collar -D-. –  Remove circlip for 3rd gear and 4th gear synchronising hub and note thickness of circlip.

–  Pull off 3rd speed selector gear with synchronising hub for 3rd and 4th gear. A  -  Puller, e.g. -Kukko 18/2-   Note Counter-hold puller-A- using e.g. gearbox bracket -2004- to prevent plate - T40086- from making contact with 3rd gear wheel or selector rod for 5th and 6th gear. –  Remove circlip for 3rd speed selector gear needle bearing and detach 3rd gear needle bearing.

–  Pull off thrust washer -B- for 3rd speed selector gear. A  -  Two-arm puller, e.g. -Kukko 20/10- with puller hook, length 250 mm

–  Remove circlip for 3rd gear wheel and note thickness of circlip. –  Pulling off 3rd gear wheel A  -  Two-arm puller, e.g. -Kukko 20/10- with puller hook, length 250 mm

–  Unscrew bolts -arrows- for reverse shaft support. –  Unscrew the 2 bolts -A- for bearing housing at gearbox housing. –  Remove the bearing housing -B- together with the shafts.

–  Insert a fin or an inside extractor -A- into the borehole of the support / reverse gear support, for example -Kukko 21/2-. –  Spread open internal puller far enough for it to make contact with reverse shaft support -B-. –  Drive reverse shaft support carefully out of bearing housing -direction of arrow- and remove with reverse gear wheel.

–  Now pull out input shaft -A- carefully from bearing housing at an angle from the front -direction of arrow-.

–  Pull pin with clip -A- for securing selector fork for reverse gear out from selector rod -B-. l  Using a felt pen, for example, mark the mounting position of the sliding sleeve of the synchromesh hub -arrow-. –  Detach selector fork -C- with locking collar -D-.

–  Press off synchronising hub for reverse gear from output shaft.   Note Place the bearing housing onto thrust plates -VW 401- and -VW 402- so that the output shaft and selector rods are not damaged when pressing off the synchronising hub. –  Detach reverse selector gear, needle bearing for reverse selector gear and reverse gear synchronising hub. –  Guide output shaft out of selector fork for 1st and 2nd gear and bearing housing.