SEAT Workshop Service and Repair Manuals

Removal: –  Remove gearbox → Chapter. Remove the bevel box from the manual gearbox as follows: –  Attach the gearbox to the stand → Chapter. –  Fit tray -T20173- beneath gearbox.

–  Unscrew the bottom bolts -arrows- for fixing the bevel gear to the gearbox. –  Unscrew the top bolts for fixing the bevel gear to the gearbox.

A heat shield -arrow A- is installed on top of bevel box in some vehicles. The bolt -arrow B- can be reached from the lower side of the heat protection plate. The bolt -arrow C- can be reached from the upper side of the heat protection plate. –  Carefully remove the bevel gear from the gearbox and secure against falling down. –  Take out bevel box. –  Rotate the gearbox on the assembly frame so that the oil plug bolt is downwards. –  Drain gearbox oil. –  Remove the conical bolt of the right flange shaft using the "1/4" threading die mount" -T20203A-.

–  Unscrew bolts -arrows-. –  Remove slave cylinder together with release bearing -A-.

–  Remove seal for input shaft by levering with the adapter -T20143/1 -.   Note Do not damage running surface of input shaft for oil seal.

–  Fill space between sealing lip and dustcap -arrow-, halfway, with sealing grease → Spare parts catalogue. –  Fit seal flush with installation tool -T20130 -

–  Remove left flange shaft.

Remove the gearbox mechanism shaft cover   Note During the following sequence, a check should be made that the selection shaft is not blocked by the retaining bracket -arrow-. –  Place the gearbox mechanism shaft in the neutral position; to do this release the locking pin -arrow-. –  Unscrew the locking pin -2-. –  Remove bolts -3-. –  Remove the gear selection mechanism shaft -4- from the gearbox casing.   Note Ignore -item 1-. –  Remove the flanged shaft and insert shaft.

–  Unscrew the bolts -B- securing the gearbox housing from the clutch housing.   Note One of the bolts -arrow- is outside the joint flange. This is fitted with a washer. –  Pierce the rubber seal cover for the centre using a screwdriver. Sheet metal cover plate

–  Remove retaining ring -A- for input shaft sealing cover.

–  Remove the rubber seal cover from the gearbox using the extractor kit -T20140 -.

Plastic cover plate Carefully remove all lugs -A-. When doing this, do not damage gearbox housing.

–  Lever out the cover plate. l  Ensure any cover plate components are removed. Continuation for all vehicles

–  Detach circlip -C- from the ball bearing on input shaft as follows: –  Support one of the securing ring ends using a screwdriver -A-. –  Release the other end of the securing ring from the ball bearing groove -arrow- using a second screwdriver as a lever -B-. –  Continue to undo the securing ring with the screwdriver -B-.

–  Unscrew bolts -A-. –  Heat the gearbox casing, at the input shaft ball bearing allotment, using the hot air blower -SAT 1416- for about 10 minutes until a temperature of about 100 °C.

–  Secure support bridge -U-40007- for input shaft to clutch housing.

–  Remove the gearbox casing from the clutch housing -arrow- using the pressure tool -T20187 -.   Note If necessary, apply an assembly lever carefully to the edges of the gearbox housing to undo it, changing from one side to another without causing damage to the sealing surfaces.   Note

To remove shafts from clutch housing, a second mechanic is required. –  Lift the differential -1- and simultaneously lift the secondary shaft of the 1st to 4th gear with the selector rods -2-, -arrow A-. –  At the same time, the second mechanic must remove the primary, inverter and secondary shaft of the 5th / 6th gears -3-, along with the control rods, out of the clutch housing -arrow B-.   Note In case of doubt, the differential may rest on the clutch housing after lifting the shafts. –  Removing the input shaft oil seal → Chapter.