SEAT Workshop Service and Repair Manuals

Removal: –  Remove gearbox → Chapter. –  Mount gearbox on assembly stand → Chapter. –  Fit tray -T20173- beneath gearbox. –  Drain gearbox oil.

–  Unscrew securing bolt of left flanged shaft arrow. To do this, screw two bolts into flange and immobilise shaft with a lever. –  Unscrew the flanged shaft with the compression spring, thrust washer and conical ring.

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

–  Take out the bushing pin -arrow- and remove the fork of 5th gear -1-. –  Using the pliers -A-81124-, remove the circlip -2- for the 5th gear synchroniser body. –  Using the pliers -A-81124-, remove the circlip -3- for the 5th gear mobile pinion. –  Remove the 5th gear movable sleeve.

–  Remove the hub and the synchronous ring of the 5th gear. For this purpose, fit the bridge with bolt - U 40100/1- at that location on the synchronous ring where the greatest contact surface to the hub is.

–  Unscrew the bolts -A- securing the input shaft and secondary shaft bearing allotment. –  Unscrew the nut with the collar -B- from the gear operation mechanism (to secure the reverse gear). –  Turn gearbox in support bracket so that clutch housing is upwards.

–  Unscrew securing bolt of right flanged shaft arrow. To do this, screw two bolts into flange and immobilise shaft with a lever. –  Unscrew the flanged shaft with the compression spring, thrust washer and conical ring.

–  Remove securing spring -arrow- on clutch release lever. –  Unscrew bolts and -1 and 2-. –  Remove clutch release lever with clutch release collar and guide sleeve.

–  Unscrew the 18 clutch housing attachment bolts -arrow- –  Lever up the gearbox casing carefully and on both sides, one after another in order not to damage the sealing surface.   Note Do not tilt the clutch housing to prevent damage to the roller bearings or their seating in the input and lay shafts.

–  Remove differential -A- from gearbox housing.

–  Remove the selection shaft along with the cover of the gear mechanism -A-. To do this, the selection lever must be moved to neutral position. –  Remove all of the bolts -arrows- and take out the gear operation mechanism from the gearbox housing along with the gear mechanism cover from the gearbox casing. –  Take the bearing bush pins -B- out of the upper part of the gearbox. –  Remove the reverse light switch -F4--C-.

–  Unscrew the bolt -A- securing the reverse gear pinion shaft. –  Take the bearing bush pins -B- out of the upper part of the gearbox.   Note Do not remove the cover -arrow- to disassemble the gearbox.

–  Release the input shaft, secondary shaft, the bearing bush allotment, the gear operation mechanism (prongs) and the reverse gear pinion together using the plunger - T10085 -.   Note t  Fit the gearbox casing onto the press plates so that the casing adjustment sleeves are not damaged in any way. t  When pressing out, get help from second mechanic to ensure components do not fall out.

Remove the radial bearing housing –  Move the locking collar of the 1st and 2nd gears towards the 2nd gear. –  Push the pressure plate -T10084A - into the input shaft from one side until as far as it will go. –  Fit the centering pins of the tool -T10081- into the holes on the input and secondary shafts.   Note When pressing out, get help from second mechanic to ensure components do not fall out. –  Release the input and secondary shafts from the bearing bush allotment. –  Remove the bearing bush allotment. –  Disassemble the input shaft if necessary → Chapter. –  Disassemble the secondary shaft if necessary → Chapter.