SEAT Workshop Service and Repair Manuals

Fitting –  Insert the input shaft -1- and the secondary shaft for the 5th/6th and reverse gear -2-, along with the control rod -3-, the prong -4- and inverter shaft -5- onto the clutch housing.   Note

To fit the shafts from the clutch housing, a second mechanic is required. –  Place the differential on the clutch housing.-1-. –  Suspend the secondary shaft for the 1st to 4th gears -3- along with the control rods -4-, as shown in the illustration. –  Lift the differential a little. –  At the same time, the second mechanic must lift the input shaft and the secondary shaft for the 5th/6th and reverse gears-2- along with the inverter shaft. –  Now fit the secondary shaft for the 1st to 4th gears in the -direction of the arrow-. l  The input shaft, secondary shaft and crown teeth should all be engaged –  Using the help of the second mechanic, press the shafts and the differential into their seats.

–  Fit the input shaftretention tool -U-40007- to the clutch housing.   Note For clarity, the clutch housing appears rotated 180 º. –  Screw in the centre bolt of the counterhold -U-40007- until the input shaft rests partially on the tool. –  Heat the gearbox casing, at the input shaft ball bearing allotment, using the hot air blower -SAT 1416- for about 10 minutes until reaching a temperature of about 100 ºC. –  Connect the gearbox casing to the clutch housing and the ball bearing of the input shaft. –  Fit the securing ring for the ball bearing of the input shaft. –  Remove the holding tool -U-40007-.

–  If the insertion sleeve for the selection shaft was removed it must be fitted using the tool -T20188- to the limit of the tool with the gearbox housing. –  Rotate the gearbox on the assembly frame so that the opening for the selection shaft is upwards.

–  Fit the selection shaft -1- into the lower allotment -2- and onto the prongs -3-.   Note For clarity, the seal plug is removed.

–  Press the selection rod -1- against the retention sleeve -2-, -arrow-, and face it under the operation finger -3-, of the prongs, to the limit. l  While doing this, the gear mechanism cover -4- should remain parallel to the surface where the gearbox housing is bolted l  The selection shaft should be easily moved upwards and downwards (selection movement)   Note If the gear mechanism cover is inclined relative to the bolted surface, this means that the selection shaft is not inserted in the lower allotment.

–  Tighten the bolts -3- for the gearbox mechanism cover -4-. Tightening torque → Item. –  Secure the retaining bolt -2-. Tightening torque → Item, for this, the anchor pin -arrow- for the selection shaft lock must be in rest position. –  Screw in the reverse light switch -1- Tightening torque → Item. –  Fit the left flanged shaft. –  Fit input shaft seal → Chapter. –  Fit the clutch slave cylinder with the release collar. → Item –  Engage all gears one after the other. –  Insert the enclosure plate, to the limit using the tappet -T20130-, on to the gearbox housing. → Fig. Fit the bevelled gears to the manual gearbox as indicated below: –  Displace the bevelled gears until it abutts the manual gearbox and join, when centred, the primary shaft pinion/bevelled gears with the differential. –  Ensure the right drive shaft pinion fits with the bevelled gear of the differential, rotate the flanged shaft if necessary. –  If the position of the pinion is correct and it is centred, the bevelled gears will slide into position against the manual gearbox.   Note Do not bring the bevelled gears towards the gearbox by tightening the fastening bolts, because the bevelled gears will tilt and may break the fastening rings. –  Remove the pair of bevelled gears → Chapter –  Attach the conical bolt for the right flanged shaft using the wrench -T20203- . –  Install gearbox → Chapter.