SEAT Workshop Service and Repair Manuals

Dismantling and assembling gearbox housing Overview: Gearbox disassembly → Chapter. Dismantling gearbox → Chapter. Assembling gearbox → Chapter. Dismantling and assembling clutch housing → Chapter. Dismantling and assembling outer input shaft → Chapter. Dismantling and assembling inner input shaft → Chapter. Dismantling and assembling output shaft 1 - overview → Chapter. Dismantling and assembling output shaft 2 - overview → Chapter. Dismantling and assembling output shaft 3 - overview → Chapter. Notes on gearbox adjustment → Chapter. Calculating shims for clutch housing → Chapter. Calculating shims for gearbox housing → Chapter. Gearbox identification → Chapter. Code, engine allocation → Chapter.

Special tools and workshop equipment required

t	pressure tool -2050-

t	Wedge -T10357-

t	Mounting part -T10380-

t	pressure tool -T10428-

t	Tensioning tool -VW 402-

t	Remove the sleeve -VW 470-

t	pressure tool -VW 473-

t	Internal puller (ø 45 to 58 mm) -KUKKO 21/7-

1 -

Gearbox

q	With oil guide → Fig.

2 -	Retainer washer

q	Smooth side faces outwards

3 -	Differential shim

q	Determining thickness → Chapter

4 -	Differential bearing race

q	Pressing out → Fig.

q	Pressing on → Fig.

5 -	Output shaft shim 3

q	Determining thickness → Chapter

6 -	Output shaft bearing race 3

q	Pulling out → Fig.

q	Preparing for pressing in → Fig.

q	Pressing on → Fig.

7 -	Output shaft shim 2

q	Determining thickness → Chapter

8 -	Output shaft bearing race 2

q	Pulling out → Fig.

q	Preparing for pressing in → Fig.

q	Pressing on → Fig.

9 -	Output shaft shim 1

q	Determining thickness → Chapter

10 -	Output shaft bearing race 1

q	Pulling out → Fig.

q	Pressing on → Fig.

11 -	Bearing for the inner input shaft

q	Remove to press out retaining ring

q	Press in »new« bearing → Fig.

12 -

Circlip

q	Always replace.

Press in bearing for inner input shaft –  Drive in the bearing to the end. Use the press tool -VW 473- for this purpose. –  Install »new« retaining ring.

Installation position of oil guide in gearbox housing –  Oil guide is clipped into housing.

Pull out bearing races of output shafts All bearing races of output shafts 1 to 3 are removed »in the same way«. Here, for example, the removal of output shaft 1 is described. Bearing races of output shafts 2 and 3 are removed in the same manner. –  Make sure that bearing race does not »get stuck« on supports of puller.

Pressing in output shaft bearing race 1 –  Insert shim. –  Press in bearing race to stop.

Prepare bearing races of output shafts 2 and 3 for pressing in –  First insert 1 shim into housing. –  Then position »correct« bearing race and drive bearing race in using targeted, light taps until it can no longer drop out.

–  Fit spacer sleeve -T10428- and press tool -VW 402- onto press.

Pressing in bearing races of output shafts 2 and 3 This shows how bearings of output shaft 2 are pressed in. -A- Output shaft bearing race 2 -B- Output shaft bearing race 3 –  To press in bearing of output shaft 2, place housing on thrust piece -B-.

Driving out bearing race of differential Bearing is driven out using a suitable drift. –  Before driving out, place ring of thrust pieces for drive pinion bearing -VW 470- under bearing. –  To prevent gearbox housing from rocking, also insert wedge -T10357- under housing.

Pressing in bearing race of differential A second mechanic is required for driving in. –  Place thrust piece -T10380- on edge of workbench. Position gearbox housing with area of bearing point on thrust piece, and hold housing firmly like that. –  A second mechanic inserts the oil ring and the shim. Using the thrust piece -2050-, the 2nd mechanic will drive in the bearing as far as the stop.