SEAT Workshop Service and Repair Manuals

Installation l  A new grooved ball bearing has been pressed onto the input shaft → Item.

–  Insert the input shaft -1- as well as the output shaft for 5th / 6th gears and reverse gear -2- together with selector rod -3-, selector fork -4- and reverse shaft -5-.   Note

A second mechanic is required for installing the shafts in the clutch housing. –  Insert the differential in clutch housing -1- –  Using one hand, lift the 1st - 4th gear output shaft -3- upwards together with the selector rods -4- as illustrated. –  Slightly lift the differential. –  At the same time the second mechanic must lift the input shaft as well as the output shaft for 5th / 6th and reverse gear -2- slightly, together with the reverse shaft. –  Now insert the secondary shaft for the 1st to 4th gears in the -direction of the arrow-. l  The input shaft, secondary shaft and crown teeth should all be engaged –  Using the help of the second mechanic, press the shafts and the differential drive into their seats.

–  Secure support bridge -U-40007- for input shaft to clutch housing.   Note For clarity of illustration, clutch housing is shown turned 180°. –  Screw the centre screw of the -U-40007-retaining tool until the drive shaft partially contact the tool. With certain gearboxes, there are flattened locations -A- on the ball bearing of the input shaft and on its mount -B-.

Check the ball bearing of the input shaft and the gearbox casing.

Check the grooved ball bearing of the input shaft and the gearbox casing.

Without flattened location on the grooved ball bearing -A- or on its mount -B- → Anchor

With flattened location on the grooved ball bearing -A- and on its mount -B- → Fig.

Gearboxes manufactured from week 15.06 up to approx. week 04.08: A washer is fitted on the top and the bottom of the groove ball bearing of the input shaft → Item

Upper washer	Outer diameter	78.6 mm
Lower washer	Outer diameter	85 mm

Measure the recess above the mount of the grooved ball bearing.

Recess on top of the grooved ball bearing	Dimension „a“	Upper washer
For gearboxes that have been manufactured from week 14/06	10 mm	no
For gearboxes that have been manufactured from week 15/06	10.7 mm	Yes

In the gearbox, the area below the mount of the groove ball bearing -arrow- has also been modified.

Area underneath the bearing housing		Lower washer
For gearboxes that have been manufactured from week 14/06	No change.	no
For gearboxes that have been manufactured from week 15/06	Has a deeper design.	Yes

–  If necessary, mount a washer (outer diameter = 85 mm) -1- on the grooved ball bearing -2-.

With certain gearboxes: With flattened location -A- on the grooved ball bearing of the input shaft and on its mount -B- l  A washer must not be mounted on the top nor the bottom of the ball bearing. l  The flattened area -A- of the ball bearing must correspond with the flattening of the mount -B- that is in the gearbox casing for this purpose. –  Mark the flattened area in colour. –  Extend the marking up to the top side of the ball bearing and the bearing housing in the gearbox casing (⇒ following Fig.). –  Using the hot air blower -SAT 1416-, heat the gearbox casing, in the area of the input shaft groove ball bearing mount for approx. 10 minutes until a temperature of about 100 ºC.   Note t  Heating is necessary to ensure that grooved ball bearing is not damaged when installing gearbox housing.

t  Align the marking of the ball bearing -A- to the gearbox casing -B- and mount the gearbox casing above this. –  With all gearbox types, use the hot air blower -SAT 1416-, heat the gearbox casing, in the area of the input shaft groove ball bearing mount for approx. 10 minutes until a temperature of about 100 ºC. –  Apply the sealing compound equally on the surface of the clutch housing to be sealed → Spare parts catalogue.

–  Fit the gearbox housing and tighten the new screws -A-, -B- and -C- with the specified tightening torque. Allocation of bolts: A  -  Bolts and washers B  -  Bolt without washer C  -  Bolts and washers

–  If a washer has been placed over the grooved ball bearing of the gearbox housing before mounting, a washer -1- (outer diameter = 78.6 mm) must be also refitted after mounting the gearbox housing -2 - → Anchor. –  Fit the circlip for the grooved ball bearing of the input shaft. –  Extract the counterhold -U-40007 -.

–  If the insertion sleeve for the selection shaft was removed it must be fitted using the tool -T20188 - to the limit of the tool with the gearbox housing. –  Rotate the gearbox on the assembly frame so that the opening for the selection shaft is upwards.

–  Fit the selection shaft -1- into the lower allotment -2- and onto the prongs -3-.   Note For better clarity, sealing cover is removed in illustration.

–  Press the selection rod -1- against the retention sleeve -2-, -arrow-, and face it under the operation finger -3-, of the prongs, to the limit. l  While doing this, the gear mechanism cover -4- should remain parallel to the surface where the gearbox housing is bolted l  The selection shaft should be easily moved upwards and downwards (selection movement)   Note If selector shaft cover is tilted relative to bolting surface, selector shaft is not inserted in lower bearing.

–  Tighten bolts -3- for selector shaft cover -4-. Tightening torque → Item –  Attach fastening screw -2- Tightening torque → Item, for this, the anchor pin -arrow- for the selection shaft lock must be in rest position. –  Install the reversing light switch -1-. Tightening torque → Item

–  Install flange shafts together with springs, thrust washers and tapered rings. –  Fit the input shaft oil seal → Chapter. –  Fit the clutch slave cylinder with the release collar. → Item –  Successively select all gears.

–  Insert the sealing cover using the pressure tool -T10042 - as far as possible in the gearbox housing. –  Fitting the gearbox → Chapter