SEAT Workshop Service and Repair Manuals

Gearbox housing - assembly overview   Note Mount gearbox on assembly stand → Chapter.

1 -

Gearbox

q	If this is replaced then the secondary differential shafts must be adjusted → Chapter

2 -	Sealing cap

q	Removing → Fig.

q	Driving in → Fig.

3 -	Oil empty plug

q	Hexagon socket head bolt, 30 Nm

4 -

Seal

q

replace

5 -	Oil filler plug

q	Hexagon socket head bolt, 30 Nm

6 -	Locking pin

q	For adjusting selector mechanism → Chapter

q	Can be renewed with gearbox assembled

q	Removing → Fig.

q	Installation position → Fig.

q	Driving in → Fig.

7 -	Bearing sleeve for the control rods

q	Remove → Fig.

q	Driving in → Fig.

8 -	Stop sleeve

q	Remove with the gearbox disassembled

q	Driving in → Fig.

9 -	Point crown for the inverter shaft

q	Always renew if removed

q	Remove → Fig.

q	Driving in → Fig.

10 -	Outer ring of roller bearing

q	For 5th/6th and reverse gear output shaft

q	Removing and installing → Fig.

q	If renewed: Adjust 5th/6th and reverse gear output shaft → Chapter

11 -

Shim

q	For 5th/6th and reverse gear output shaft

q	Adjustment overview → Chapter

12 -	Outer ring of roller bearing

q	For 1st to 4th gear output shaft

q	Removing and installing → Chapter

q	If renewed: Adjust 1st - 4th gear output shaft → Chapter

13 -

Shim

q	For 1st to 4th gear output shaft

q	Adjustment overview → Chapter

14 -	Outer ring of roller bearing

q	For the differential

q	Removing and installing → Chapter

q	If replaced the differential must be replaced → Chapter

15 -

Shim

q	For the differential

q	Adjustment overview → Chapter

16 -	Bearing socket for operation mechanism shaft

q	Remove → Fig.

q	Driving in → Fig.

17 -	Sealing plug

q	Press and drive in → Fig.

18 -

Seal

q

replace

Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Tappet -T10203-, see equivalent → Anchor

t	Hose clamp -T20129-, see equivalent → Anchor

t	Tappet -T20130-, see equivalent → Anchor

t	Extractor kit -T20140-, see equivalent → Anchor

t	Kit (case) -U 40200A-, see equivalent → Anchor

t	Tappet -U-40204-, see equivalent → Anchor

t  Tappet -T20139-, see equivalent → Anchor

t  Tappet -T20188-, see equivalent → Anchor

Removing sealing cap –  Pierce the rubber centre of the plug seal -A- with a screwdriver -B- and lever off the cover -arrow-.

Insert the cover with the -T20130-adapter.

Remove the gearbox mechanism locking pin –  Remove the fastening bolt in unlocked position. –  Insert a screwdriver -A- though the hole -B- of the locking pin. –  Unscrew the locking pin -arrow-.

Locking pin installation position The mark -arrow- in the locking pin should point to the connection -1- of the clutch slave cylinder. The angle -a- should be about 45°.

Fit the gearbox mechanism locking pin l  The locking pin -arrow- should be unlocked when it is inserted. –  Insert the locking pin until the limit of the tool.

Pulling out selector rod bearing bush –  Extract the bearing sockets using the adapter -T20129- and the pressure tool -T20140/14- .

Insert the bearing sleeve for the control rod until it is flush –  Fit the socket with the end -B- of the installation tool -U-40204-.

Release the insertion sleeve with the gearbox disassembled using the tool -T20188- –  Release the insertion sleeve using the installation tool -T20188- using the lowest diameter. l  Locking bolt and the selection shaft are removed –  Rotate the gearbox so that the insertion sleeve does not fall inside.

Insert the insertion sleeve with the gearbox assembled using the tool -T20188- l  The gearbox casing is bolted to the clutch housing –  Insert the insertion sleeve using the insertion tool -T20188- to the limit of the tool using the largest diameter.

Extract the points crown for the shaft from the gearbox housing –  Extract the bearing sockets using the adapter -T20140/1- and the pressure tool -T20140/14- . l  The same disassembling process is used for both the gearbox and the clutch housings

Insert the points crown for the inverter shaft into the gearbox housing –  When inserting the thrust washer for the inverter shaft -B- must be fitted onto the points crown -A-. –  Support the gearbox casing by fitting the adapter -U-40200/20- directly underneath the bearing allotment.

Remove the bearing socket for operation mechanism shaft –  Extract the bearing bush for the selection rod using the pressure tool -T20129- and the kit (case) -U 40200A-.

Fit the bearing socket for operation mechanism shaft –  Fit bearing socket -A- with installation tool -U-40204-.

Extract and insert the seal plug from the outside –  Release the seal plug from the outside with the tool -T20139- using the lowest diameter. –  Insert the seal plug from the outside with the tool -T20139- using the largest diameter.