SEAT Workshop Service and Repair Manuals

Installation   Note t  Insert the allotment with grooved ball bearings for the input and secondary shafts → Fig.. t  Pressing sleeve for 5th speed selector gear needle roller bearing onto input shaft → Fig..

If the 5th speed selector gear cannot be extracted. –  Once assembled, fit the input shaft -2-, the secondary shaft -1- with the grooved ball bearing allotment on the pressure tool -T10080 -. –  Insert selector mechanism (selector forks) -4- in the shaft locking collars. –  Fit the reverse gear shaft -3- with the pinion. –  Screw in the guide sleeve -T10079- on the reverse gear threaded attachment pin -arrow-.

If the 5th speed selector gear can be extracted. –  Position assembled components, input shaft -2- and output shaft -1- with bearing mounting for deep groove ball bearing, in thrust piece -T10080-. –  Insert selector mechanism (selector forks) -4- in the shaft locking collars. –  Fit the reverse gear shaft -3- with the pinion. –  Screw in the guide sleeve -T10079- on the reverse gear threaded attachment pin -arrow-. Continuation

–  Put all of the components together in the gearbox casing inserting the guide pin -T10079 - through the hole where the gear operation mechanism is to fitted to the gearbox casing. –  Unscrew the guide pin -T10079 -.. Note the following before pressing in: t  Selector forks engage correctly in locking collars.

t  The spacing -a- on the splines of output shaft.   Note t  Due to different spline heights, dimension -a-, output shafts of individual gearboxes have different lengths. t  A shim -T10083/1- (3mm thick) may have to be fitted on the input shaft to ensure that the input shaft and the output shaft are always pressed in evenly. t  This is the reason why dimension -a- for output shaft teeth must be measured.

Dimension -a- = 30.6 mm

Place shim -T10083/1- onto input shaft ⇒ next figure.

Place shim -T10083/1- onto input shaft and carefully press in bearing mounting together with input shaft and output shaft to stop

Carefully insert the allotment together with the input and secondary shafts to the end.

–  Install bolt -A- for securing reverse gear wheel shaft. –  Fit the bearing bush pins -B- in the lower part of the gearbox.

–  Screw the reverse light switch -F4--C-. –  Fit the bearing bush pins -B- in the upper part of the gearbox. –  Set selector plates in neutral position. –  Apply sealing paste -AMV 188 200 03- uniformly on the sealing surface of the selector shaft cover. –  Install selector shaft with selector cover -A-. Then tighten bolts -arrows-. For vehicles with start stop system

–  Mount the gearbox neutral position sender -G701 - and tighten the screws -arrow- with the respective tightening torque → Item. Continuation for all vehicles

–  Tighten the input shaft and secondary shaft allotment with new bolts -A-.   Note Tighten the bolts to the corresponding torque, in steps and diagonally, beginning at the centre. –  Tighten the hexagonal nut with collar -B- securing the gear operation mechanism (prongs). –  Place the input and lay shafts together with the gearbox casing in the base for fitting - T10083 -. –  Mount the 5th gear pinion -1- and the sleeve -2-.

Installation position of 5th gear wheel The high shoulder -arrow- faces gearbox housing cover. If the 5th speed selector gear cannot be extracted. –  Install gear wheel for 5th gear -1- and sleeve -2-.

If the 5th speed selector gear can be extracted. –  Pressing on gear wheel for 5th gear –  Set sleeve on gear wheel for 5th gear item -2-. Continuation –  Fit the mobile 5th gear pinion -3- with the needle bearing. –  Place 5th gear synchro-ring on synchromeshed gear.

Installation position for mobile and 5th / 6th gear synchromesh The highest collar -arrow- must face towards 5th gear and the gearbox casing. –  Press on synchro-hub and locking collar for 5th and 6th gear → Fig..

–  Heat the inner ring of the needle bearing of 6th gear to a maximum of 100°C and fit.   WARNING Wear protective gloves! –  Install synchromeshed gear for 6th gear with needle bearing and synchro-ring.

–  Fit the thrust ring -A- on top.   Note Do not interchange inner races of cylindrical roller bearings of input and output shafts. –  Heat the roller bearing inner ring -B- to approx. 100 ºC, and fit it onto the input shaft.   WARNING Wear protective gloves!

Installation position of 6th gear wheel: The high collar should be facing the sleeve. –  Set the locking collar -A- for 5th / 6th gear to neutral position to allow 6th speed selector gear to turn while pressing on 6th gear wheel. –  Heat gear wheel for 6th gear to maximum 100° C.   WARNING Wear protective gloves! –  Fit the gear pinion for 6th gear. Make sure that its teeth-B- and that of the mobile pinion -C- match.

–  Heat the roller bearing inner ring -A- to approx. 100 ºC, and fit it onto the lay shaft.   WARNING Wear protective gloves!

–  Next, place the oil collector -A- in the recess -1- and in the drill hole -2- of the gearbox casing.

–  Mount the oil guide -B- on the gearbox casing. –  Place the magnet on the oil guide -B-.

–  Install differential -A-. –  Apply an even coat of sealant paste -AMV 188 200 03- on the sealing surface. –  Secure clutch housing to gearbox housing. –  Rotate the gearbox on the assembly stand so that the gearbox casing is facing upwards.

–  Before tightening the fastening bolts -A- 2 gears should be engaged -arrow 1- to -arrow 3-.

–  Insert the 5th / 6th gear selector fork -2- and slide the pivot pin -1- in onto stop in direction of -arrow-. –  Apply an even coat of sealant paste -AMV 188 200 03- on the sealing surface. –  Tighten screws to secure the gearbox casing cover.

–  Install both flange shafts with springs, thrust washers and tapered rings. –  Fit the clutch release lever with clutch release collar and guide sleeve .