SEAT Workshop Service and Repair Manuals

Removal: –  Remove gearbox → Chapter. –  Mount gearbox on assembly stand → Chapter. –  Fit tray -T20173- beneath gearbox. –  Empty the gearbox oil → Chapter. –  Remove clutch release socket and clutch release prong → Chapter. –  Unscrew guide bush securing bolts → Chapter   Caution When removing the gearbox casing, some remaining gear oil may drip.

–  Remove the bolts -arrows- and remove the gearbox casing cover.

Remove selector fork for 5th gear as follows: –  Cover over openings with a cloth. –  Move selector fork -1- to neutral. –  Remove the screw -2- together with the connecting support for 5th gear. –  Then remove both bolts -arrows- for pivot pins. –  Pull out pivot pins. –  Remove the gear change prongs -1- and the locking pin. –  Spring -3- and locking collar -4- do not need to be removed.

In order to slacken 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. –  Slacken and remove bolts -A-.   Note If shafts are not to be renewed, carefully clean residual locking material out of the tapped holes using a thread tap.

–  Remove the two bolts -arrows- supporting the reverse gear shaft.

–  Remove the bolt -arrows- supporting the reverse gear shaft.

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

Continuation for all vehicles –  Place the gear selection drive shaft in neutral. Remove the attachment bolts -arrows- and remove the gear selector rod from the gearbox housing.

–  Remove the dust sleeve cover -A- and the support bolts -B- from the lower part of the gear box, previously removing bolts -arrows 1 and 2-.

–  Remove support bolts -A- from upper part of gearbox and bolts -B- for securing gearbox casing to clutch casing.

–  Remove bolts -A- to secure the clutch housing to the gearbox casing.   Note Do not remove the nuts -B- for fitting the secondary shaft.

–  Remove both flange shafts. –  Take out flange shafts together with springs, thrust washers and tapered rings.

Pull off following components together with gearbox housing: t  Synchromesh ring for 5th gear. t  5th gear mobile pinion. l  Both grips -T10408/3- must be secured on the 5th gear mobile pinion. l  The grips -T10408/3- must always be positioned above the two housing ribs, which are located opposite each other -arrows-.   Note t  There is a needle bearing beneath the 5th gear mobile pinion. t  Secure the grips -T10408/3- so that the bearing does not come in contact with the gear wheel for 5th gear when the gearbox housing is pulled off.

Use puller plate -T10408- in conjunction with following special tools: t  Thrust blocks -T10408/2- t  Tabs -T10408/3- t  Puller Kukko 18/1 –  Screw puller plate -T10408- firmly into threaded holes for gearbox housing cover. A -  Hexagon bolts M7 x 35 with washers Tightening torque: 18 Nm –  Place thrust pieces -T10408/2- on shafts.

–  Mount extractor -KUKKO 18/1--A-.   Caution In order to remove the 5th gear wheel, heat to approx. 100 °C with hot air blower -SAT 1416- –  Pull off 5th gear synchro-hub, gear wheel for 5th gear mobile pinion and gearbox housing by alternately tightening spindles -A- (approx. 1 2 turn).

–  Remove the prongs -A- with the connection guides. –  Remove the bolt -B-, and extract the reverse gear prong.

–  Remove the nuts -B- for fitting the secondary shaft.   Note Placing the gearbox shafts vertically before removing all nuts -B-.

Shafts -C- and -B- with reverse gear axle –  Remove clutch casing by order, reverse gear shaft -A-, input shaft -B- and secondary shaft -C-. –  Remove the differential set from the clutch housing.