Dismantling and assembling gearbox

Make

SEAT

Model

Leon Mk1

Section

6-speed manual gearbox 0A6 › Gearbox mechanics,operation, construction,diff. › Dismantling and assembling gearbox

Power transmissionDismantling and assembling gearbox

Removing –  Secure gearbox to engine and gearbox support -VW 540- → Chapter.

–  Remove slave cylinder with clutch release bearing -arrows A-. Gearbox for front-wheel drive –  Remove securing bolt for right stub shaft -arrow B-. –  Pull out stub shaft. Continuation for all vehicles –  Place drip tray under the engine. –  Drain gear oil. –  Remove bolts for securing clutch housing to gearbox housing.

–  Lock input shaft -B-, to do this place the installing sleeve -VW 455- over the input shaft on the clutch housing. –  Secure splitter 5 ... 60 mm-A-, for example splitter with quick clamping spindle (inner diameter 5 - 60 mm) -KUKKO 17/0-, behind the input shaft splines. l  No play can be present between splitter and installing sleeve.

–  Gearboxes for vehicles with start-stop system: remove gearbox neutral position sender -G701--arrow-. –  Place selector shaft of selector unit in neutral. –  Remove reversing light switch -F4--A-. –  Remove bolts for selector unit -B- from gearbox housing. –  Pull selector unit out of gearbox housing while turning selector unit 180°. l  Selector fingers of selector unit must be guided through selector rods. –  Remove hexagon nuts -C-.

–  If present, remove tachograph sender -G75--A--arrow-.

–  Remove locking plate -1-.

–  Or remove retaining clip -2-.

–  Pierce rubber in centre of cover plate -C- with a screwdriver. –  Pull sealing cover out of gearbox housing. –  If necessary, pull cover out of gearbox housing. A -  e. g. Counter support B -  Internal puller, 14.5…18.5 mm, e.g. -Kukko 21/02-

Remove retaining ring -C- from deep groove ball bearing of input shaft as follows: –  Hold end of retaining ring with screwdriver -A-. –  With a second screwdriver -B-, lever other end of retaining ring out of groove in deep groove ball bearing -arrow-. –  Continue to lever out retaining ring with screwdriver -B-.

–  Unscrew securing bolts from the left stub shaft -A-, to do this the stub shaft must be locked using the counterhold -T10371-. –  Pull out stub shaft. –  Remove bolts securing gearbox housing to clutch housing.   Note If bolts -B- are present, they do not need to be removed in order for gearbox housing to be removed.

–  Screw multipurpose tool -VW 771/44- into threaded hole of gearbox housing to stop and counterlock with nut -A-. –  Heat the gearbox housing e.g. using hot air blower -VAG 1416- in area round bearing seats for grooved ball bearing/input shaft for approx. 10 minutes long to approx. 100 °C. –  Separate the gearbox housing from clutch housing using the multipurpose tool -VW 771-. At the same time separate gearbox housing on housing web -arrow- from clutch housing using assembly tool -B-.

–  Remove splitter -A- and installing sleeve -VW 455- from input shaft -B-.

–  Remove reverse gear selector fork -A-. –  If necessary, carefully tilt gearbox slightly to side.

–  Lift input shaft -1- in direction of -arrow-, until the pulley counterhold -3435- can be inserted. –  Swing gearbox back to original horizontal position.

–  Secure stub shaft -1- to differential so that differential can be raised during the following steps. –  Remove output shaft for 3rd and 4th gear -2- together with selector rod -3-. –  Carefully tilt gearbox slightly to side.

–  Press output shaft for 1st and 2nd gears -B- up to stop. –  Then swing reverse gear output shaft -A- out.   Caution Gearbox components might come loose inadvertently when tilted. To prevent this happening, swing gearbox back to original horizontal position. –  Then remove output shaft for 1st and 2nd gears -B- together with selector rod -C- from clutch housing.

–  Remove input shaft -1- together with selector rod -2-. –  Pull out differential -3- on stub shaft. –  Remove input shaft oil seal → Item.   Note Always renew deep groove ball bearing on input shaft ⇒ Assembly overview - input shaft → Item.

01 Transmission

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