SEAT Workshop Service and Repair Manuals

Installation –  Place the differential on the clutch housing. –  Sealing washers -arrows- must always be renewed.   Note The figure only shows 3 or 4 bolts with their O-ring gaskets.

–  Insert the input shaft -1- and secondary shaft -2- together. –  Partially diagonally screw the 4 nuts on the secondary shaft bearing cover and then tighten with a tightening torque → Item. –  Set reverse gear wheel -3- on needle bearing in clutch housing. The shoulder -arrow- faces away from the clutch housing. –  Ensure that reverse shaft -4- is complete → Chapter; do not yet fit reverse shaft support to reverse shaft. –  Fit reverse shaft into clutch housing. –  Clean all locking fluid away from all threaded holes in reverse shaft support; a thread cutter may be used for this purpose. –  Install the reverse gear shaft support

–  Mount the gear prong of the reverse gear -1- with the support for the gear prong of the reverse gear -2-, the spring -3- and the slide -4-.

Fitting position of reverse gear shaft

–  Screw in the gear selection mechanism of the reverse gear -A-. –  Install the gear prong -B- along with the selector plates.   Note Reverse shaft support -C- is located in front of selector plates.

–  Screw a M8 x 100 mm stud -A- in the reverse gear shaft support so that it is aligned after fitting the gearbox casing. –  Align the connection guides. –  Check that the change-over bolts of the gearbox prongs are housed in their respective mobile sleeves. –  Check that the magnet is not broken or cracked and place it in its housing in the clutch housing. –  Thoroughly clean contact surfaces of clutch casing and gearbox casing. Apply an even coat of sealing compound that is not too thick → Electronic spare parts catalogue (ETKA). –  Assemble the gearbox casing on the clutch housing. –  Tighten screws securing the clutch housing to the gearbox casing to corresponding torque. → Item

Install bolts for reverse shaft support -arrow- in the following order: –  Insert the bolt -a-. –  Remove stud -A- (⇒ top illustration). –  Fit bolt -c-   Note -Arrow- can be disregarded. –  Tighten bolts securing reverse gear support shaft to corresponding torque in sequence. Tightening sequence: –  Tighten bolt -a- to specified torque → Item. –  Tighten screw -arrow- (⇒ Fig. below) to specified torque → Item.

–  Tighten bolt -c- (⇒ Fig. top) to specified torque → Item.

–  Install the bearing bolts -arrow- for the gearbox prongs. Use a screwdriver to align the connection guides, so that each support bolt can be installed in its housing. –  Thoroughly clean contact surfaces of sealing cap for gear selector and casing. Apply an even coat of sealing compound that is not too thick → Electronic spare parts catalogue (ETKA). –  Install the cover on the gear selector.

Install the gear selector shaft as follows: –  Place the connection guides in neutral position. –  Move selector shaft to neutral. –  Locate lug -arrow 1- in recess in gearbox housing. Install the gear selector shaft so that connection finger -arrow 2- goes into to the engagement guides. –  Screw in gear selector securing bolts to gearbox casing and tighten to corresponding torque → Item.

Gearbox for vehicles with start stop system –  Mount the gearbox neutral position sender -G701--arrow- and tighten the screw with the respective tightening torque → Item. Continuation for all vehicles

Installation position of 5th gear pinion: –  The lobe present -arrow- on the internal diameter of the gear must be orientated towards the gearbox casing.

–  Heat the gear wheel of the 5th gear to approx. 100 °C with the hot air blower -SAT 1416-. –  Press the pinion in with the adapter -U-40200/20-.

Check 5th gear synchromesh ring for wear. –  Before checking for wear, thoroughly clean the synchroniser ring and 5th gear mesh. –  Place synchroniser ring on 5th gear mesh. Press the synchrony ring on the sprocket and measure the elevation „a“ with a thickness jig.

Synchro-ring	Measurement „a“ in new synchro	Wear limit
5. gear	1.1 ... 1.7 mm	0.5 mm

–  Fit the mobile 5th gear pinion with the needle bearing. –  Fit 5th gear synchro ring on the mobile pinion. –  Before installation, assemble 5th gear synchromesh assembly → Fig.

Assembly position of the 5th gear synchromesh/mobile element assembly –  Install the 5th gear mesh on the input shaft so that the pointed teeth on the mobile element -arrow 1- and the top collar on synchromesh body -arrow 2- point towards the gearbox casing. –  The notches on the synchromesh hub -arrow 3- are aligned with the locking pieces on the synchromesh ring.

5th gear synchromesh ring with locking pieces incorporated -arrows- –  Cover all holes with rag to prevent foreign body from penetrating into the transmission.

–  Press the synchromesh assembly onto 5th gear mobile pinion. Using the adaptor -U-40200/20-.   Note Before installing the synchromesh assembly to the gear wheel for 5th gear, check the 5th gear synchromesh ring turns freely.   WARNING Wear protective gloves! –  Clean residual locking fluid from threaded holes for synchro-hub securing bolts and 5th gear wheel with a thread chaser. Otherwise bolts can break. –  Partially screw-in the synchromesh hub and gear wheel for 5th gear securing bolts and sprocket.

Installation position of the plate spring –  The concave side of the plate springs -arrows- must be orientate towards the synchromesh hub and the gear wheel for 5th gear.

In order to tighten the two fixing bolts -A- securing 5th gear sprocket and synchromesh, take the following steps: –  Press the locking collar of 5th gear -arrow 1- downwards. –  Also connect the 1st gear by pressing the selection drive shaft inwards -arrow 2- and turning it -arrow 3-. l  After both gears are engaged, the input shaft and output shaft are locked. The synchro-hub and gear wheel cannot turn. –  Tighten bolt -A- to specified torque → Item. –  Install the 5th gear connection prong and fasten with the Torx bolts → Item.

Adjust the sliding sleeve and the prong for the 5th gear –  5. Gear engaged. Release bolt -1-, press and move in direction of arrow, then tighten bolt -1- to corresponding torque. → Item   Note The gap between the sliding pinion and the sliding gear must not greater than 0.2 mm. If necessary, repeat the adjustment process. –  5. th gear disengagement. The sleeve must be situated in neutral and the synchromesh ring must turn briefly in this position. –  Check that all gears connect easily.

–  Install the gasket and gearbox casing cover. –  Tighten fixing bolts -arrows- of the gearbox housing cover to their tightening torque → Item. –  Install guide sleeve for clutch release bearing and secure to casing → Chapter.

–  Install both flange shafts with compression springs, thrust washers and tapered rings → Chapter. –  Installing the guide sleeve and fixing screws → Chapter –  Install the clutch release socket and clutch release prong → Chapter –  Fill with gearbox oil → Chapter. –  Expose the gearbox from repair stand. –  Install the gearbox in the vehicle → Chapter.