SEAT Workshop Service and Repair Manuals

Detaching

Gearbox for turbo diesel engine –  Attach gearbox to assembly stand using bolts -arrow A- and -arrow B-.

–  Compensate for space between bolt hole -arrow B- and gearbox support -VW 353- using washers (approx. 12 mm). –  Use holes -1- and -2- for attaching.

Gearbox for petrol engine –  Secure gearbox to assembly stand with bolts -arrows-.

–  Use holes -1- and -2- for this.   Note If one of the bolt holes is not flush with the gearbox support, please insert a washer (or washers) between the bolt hole and the gearbox support. Continuation for all vehicles –  Remove slave cylinder with clutch release bearing (⇒ figure above -arrows A-). –  Turn gearbox on assembly stand with oil drain plug downwards. –  Place drip tray underneath. –  Drain gear oil.

–  Remove right flange shaft (fig. shows left flange shaft).

–  Remove bolts -B- securing gearbox housing from inside clutch housing.   Note One of the bolts -arrow- is outside the joint flange. –  Lock input shaft. The lengths of the splines on the input shaft differ to those of the gearbox.

–  Set either installing sleeve -VW 455- over input shaft on clutch housing

–  or set sleeve -3160- over input shaft on clutch housing –  Clamp splitter-A-, e.g. -Kukko 17/0-, behind notch in splines of input shaft. The rear side of the splitter must be in contact with installing sleeve (zero play).

–  Remove left flange shaft.

–  Gearbox for vehicles with start stop system Remove the gearbox neutral position sender -G701--arrow-.

During the following sequence, a check should be made that the selection shaft is not blocked by the retaining bracket -arrow-. –  Move selector shaft to neutral. –  Loosen the locking bolt -2-. –  Then remove bolts -3-. –  Remove reversing light switch -F4--1-. –  Remove the gear selection mechanism shaft -4- from the gearbox casing.

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

–  Pierce rubber in centre of sealing cap -C- with a screwdriver. –  Pull sealing cap out of gearbox housing. A -  Counter-support, e.g. -Kukko 22/1- B -  Internal puller 8...12 mm, e.g. -Kukko 21/01-

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

–  Pry out sealing cover -A-. l  Ensure any cover plate components are removed.

Continuation for all vehicles Detach circlip -C- from grooved ball bearing on input shaft/gearbox housing as follows: –  Fix one of the securing ring ends using a screwdrive-A-. –  Lever other end of circlip out of slot in grooved ball bearing in direction of -arrow- with 2nd screwdriver-B-. –  Lever circlip out further by repositioning screwdriver-B-.

–  Remove gearbox housing/clutch housing securing bolts -A-.

–  Screw the adapter VW 771/40 into threaded borehole in gearbox housing. –  Using hot air blower, e.g. -V.A.G 1416-, heat area around seat of input shaft ball bearing in gearbox housing for approx. 10 minutes to approx. 100° C. –  Using multi-purpose tool VW 771/1, pull gearbox housing off clutch housing in direction of -arrow-.   Note Remove gearbox housing; if necessary carefully apply lever at overhanging housing shoulders along perimeter alternately using assembly lever. Be careful not to damage sealing surfaces.

–  Remove splitter-A- and installing sleeve VW 455 or sleeve -3160- from input shaft. To remove shafts from clutch housing, a second mechanic is required.

–  With left hand, raise differential -1-. With right hand, lift output shaft for 1st to 4th gear together with selector rods -2--arrow A-. –  At the same time, the second mechanic must lift the input shaft, reverse shaft and 5th/6th gear output shaft -3- out of the clutch housing together with the selector rods -arrow B-.   Note After shafts are lifted, differential may be set back in clutch housing if desired. –  Lever out seal for input shaft using lever -VW 681-.   Note Always renew grooved ball bearing on input shaft → Item.