SEAT Workshop Service and Repair Manuals

Repair instructions A high degree of care and cleanliness, in addition to tools in top condition, are an important requirement to correctly and succesfully change the gearbox. Of course, the general safety regulations in force while carrying out repairs should also be observed. A series of instructions have been grouped together here, which are generally applicable to different repair operations (on the whole, they appear in many sections of the Repair Manual). These instructions must be taken into account for this Workshop Manual. Special tool In the classification list “Special tools” a summary is given of the special tools used in the Workshop Manual. Gearboxes with and without filler tube

“By way of example”, the filler tube of an “older model” of gearbox is shown here. This tube is no longer used.

Nor is the “former” filler neck with red hood necessary as the ATF can be drained and topped up through the lower hole. The “height” of this rising hose determines the height of the ATF level. t  After assembly, check and adjust the ATF level → Chapter. t  Filling amounts → Chapter . Seals

t  Before fitting the radial oil seals, fill the space between the sealing lips with grease t  Replace O-rings t  After fitting, check the ATF fluid level and top up if necessary Sealing paste t  Clean contact surfaces thoroughly and apply sealing paste → Spare Parts catalogue t  Note the use-by date of the sealant. t  After applying the sealing paste, bolt up the components within 5 minutes t  After assembly, the sealant should be dry in approx. 30 minutes Then fill with ATF Safety locks t  Do not over-stretch the securing rings, replace if necessary t  The securing rings must be perfectly seated in their groove Bolts, nuts t  The bolts or washers for fastening the covers and boxes should be loosened and tightened in diagonal pairs t  Particularly sensitive parts should not be placed on their sides, such as the slide box, for example, and should be loosened and tightened in diagonal pairs t  Tightening torques are specified for nuts and bolts without lubrication t  If the bolt threads have remains of locking paste, clean with a wire brush. Next insert the bolts using → Spare Parts Catalogue t  Always replace self-locking nuts following their removal Bearings t  Fit bearings on the gearbox using ATF t  Mount the pin axial bearings in the correct position → Chapter t  Heat the inner / roller bearing ring to 100ºC before press fitting t  Do not swap interior and exterior rings of bearings of the same size. t  Replace conical roller bearings on one shaft at the same time Where possible, replace with the same make Piston rings t  Do not open excessively when removing or fitting Shims t  Measure the adjustment washers at various points using a micrometer. Different tolerances make it possible to precisely determine the thickness of the washer required t  Check for notches or wear Only fit shims in perfect state Clutches and brakes t  The K1, K2 and K3 must be dismantled for cleaning while identifying the defective parts (for example the external rings and the internal rings) according to the replacement identification letters. t  Before fitting the piston, coat the sealing lips and oil seals with ATF

t  After fitting the clutches or brakes, it should be possible to turn the piston in both directions by hand (-arrows-). If this is not the case, the sealing lips and oil seals may hang out or be damaged –  If this is the case, remove the piston again. –  Check for damage in the sealing lips or oil seals and replace if necessary. –  Refit the piston and check again. Valve assembly t  If any control elements are burnt, the valve assembly should be replaced Inner discs

t  Fit the new inner discs, before fitting, soak in ATF for 15 minutes. Guided fault location, vehicle self-diagnosis and measurement module

t  Before any repairs to the automatic gearbox, locate the cause of the fault as precisely as possible using the central diagnosis -VAS 5051B- in operation mode“Guided fault finding”