SEAT Workshop Service and Repair Manuals

Installation sequence - Cover for gearbox casing and 5th gear with the gearbox installed: Removing and installing

Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Torque wrench kit -SAT 8010-, see equivalent → Anchor

t	Tray -T20173-, see equivalent → Anchor

t	Spanner -U 40090-

t	Extractor kit -U 40100B-, see equivalent → Anchor

t	Kit (case) -U 40200A-, see equivalent → Anchor

t	Hot air blower -SAT 1416-, see equivalent → Anchor

t	Two arm puller -T10040-

t	With puller hooks -T10040/2A-

Detaching   WARNING t  Check if the vehicle is equipped with Start-Stop system. t  If this should be the case, observe the safety precautions for vehicles with start-stop system. → Chapter –  Raise the vehicle. –  Remove front left wheel.

Diesel engine vehicles: –  Remove bolts -1 ... 3- and remove central soundproofing panel.

Vehicles with petrol engine: –  Remove bolts -1- and - 2- and remove central soundproofing panel. –  Remove left soundproofing panel: For Altea and Toledo models: → exterior bodywork; Rep. gr.66and for Leon model: → exterior bodywork; Rep. gr.50. –  Place below the collecting tray -T20173-. –  Remove the drain plug and empty the gearbox oil → Chapter.   Caution When removing the gearbox casing, some remaining gear oil may drip.

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

–  Check whether puller hooks -T10040/2A- can be inserted correctly under 5th gear wheel.

Puller hooks -T10040/2A- cannot be inserted correctly.
-A- Puller hooks -T10040/2A- make contact too soon with: t  gearbox housing wall t  ribs in gearbox housing under gear wheel	Removing the „unit “: „synchro-hub for 5th gear“, „gear wheel for 5th gear“ and „gearbox housing“ → Chapter
-B- Puller hooks -T10040/2A- come into contact with ribs in gearbox housing below gear wheel.

Puller hooks -T10040/2A- cannot be inserted correctly.

5th gear can be removed separately, ⇒ → Fig.

Remove the selector fork for 5th gear individually: –  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 5th gear movable sleeve. –  Remove synchromesh element and 5th gear mobile pinion using the bridge with bolt -U 40100/1-.   Note t  In order to remove the 5th gear wheel, heat to approx. 100 °C with hot air blower -SAT 1416- t  To avoid extractor feet bending outwards, attach adapter -U 40100/8- Make sure that the 5th gear is not damaged.

–  Remove the needle bearing for the 5th gear. –  Remove 5th gear wheel with the bridge with bolt -U 40100/1-. Installing

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“ on new synchroniser	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.

Install the synchromesh assembly for 5th gear 1 -  Circlip for the locking elements. 2 -  Locking collar with 3 recesses -arrows A- for the locking pieces -4- 3 -  Synchroniser body. 4 -  Locking keyways. Installation position: the recess -arrow B- points to the teeth terminating in the end of the sliding sleeve -2-.   Note Before fitting the assembly, check the synchromesh for wear –  Place the sliding sleeve -2- on the synchromesh bush -3- so that the base strips align -A- in order to house the locking keys -4- of both components, and the teeth terminating in the end of the sliding sleeve are situated in the same direction as the most pronounced lug -B- of the locking keys. –  Insert locking pin -4- and secure with a circlip -1-.

Installing springs with bent ends -A-   Note t  These springs are installed on both sides. t  Spring are installed only in conjunction with hollow locking pieces.

Installation location of the corrugated spring washers: –  Check that locking keys are correctly installed → Fig. –  Insert the washers offset by 120°. –  Angled end -A- of spring washer must locate in hollow locking piece. –  The spring washer must be fitted under the protrusion -B- of locking pieces. –  The offset end must always point away from synchronising hub (in direction of -arrow-).

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. –  Fill with gearbox oil → Chapter. –  Fit the drain bolt, noting the tightening torque → Item. –  Remove left soundproofing panel: For Altea and Toledo models: → exterior bodywork; Rep. gr.66and for Leon model: → exterior bodywork; Rep. gr.50.

Diesel engine vehicles: –  Install the centre noise insulation and insert the screws -1 - 3-.

Vehicles with petrol engine: –  Install the centre noise insulation and screw in the screws -1- and -2-. –  Fit the front left hand side wheel.