SEAT Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ VW 309 Holding plate
• ◆ VW 313 Support clamp
• ◆ VW 353 Gearbox support
• ◆ VW 402 Thrust plate
• ◆ VW 412 Press tool
• ◆ VW 415 A Tube

• ◆ VW 418 A Tube
• ◆ 3110 Tube
• ◆ 3267 Assembly ring
• ◆ 3336 Gearbox lifting beam

Dismantling planetary gearbox

• ● Gearbox is attached to gearbox support device 3336

• ‒ Place container under the gearbox.
• ‒ → Remove sealing plug -1- and ATF overflow pipe -2-.
• ‒ Drain ATF.

•     3 -    Sealing plug
•     4 -    Cap

• ‒ Take out torque converter.

• ‒ Seal ATF cooler connections.
• ‒ → Secure gearbox to assembly support with bolts -1- and -2-.
• ‒ Remove gearbox support device 3336.

• ‒ → Remove gearbox housing cover with gasket (arrows).

• ‒ Remove sump.
• ‒ Remove ATF screen.
• ‒ → Remove valve body with conductor strip.

• ‒ → Take out sealing plugs for -B1-.

• ‒ → Remove ATF pump bolts (arrows).

• ‒ → Screw bolts -A- (M8) into the tapped holes of ATF pump.
• ‒ Press ATF pump off gearbox by turning the bolts -A- evenly.

• ‒ → Take out all clutches with supporting tube, -B2- plates, springs and spring caps together.

On some gearboxes the clutches -K1- and -K3- may be pressed together.

Clutch -K1- must only be pressed off -K3- if one of the clutches is to be dismantled or renewed.

Pressing -K1- off -K3- .

• ‒ → Insert screwdriver through hole of large sun gear to loosen and tighten bolt for small input shaft.

• ‒ → Loosen small input shaft bolt -arrow-.
• ‒ Remove small input shaft bolt, washer and shim.

• Planet carrier axial needle bearing remains in gearbox/input gear.

• ‒ Pull out small input shaft.

• ‒ → Pull out large input shaft (arrow).

• ‒ → Pull out large sun gear (arrow).

• ‒ Remove gearbox speed sender -G38-.

=> Repair group 01; Electrical/electronic components and fitting locations

• ‒ → Remove supporting tube circlip -a- and freewheel circlip -b-.
• ‒ Take freewheel out of gearbox housing by pulling on freewheel retaining wedge -arrow- with pliers.

• ‒ → Pull out planet carrier with dished spring.
• ‒ Remove reverse gear brake -B1- plates.

• ◆ It is not necessary to remove input gear to dismantle planetary gearbox. Removing and installing input gear => Page 39-30.
• ◆ Assembling planetary gearbox => Page 37-86.

Pressing clutch -K1- off -K3-

On some gearboxes the clutches -K1- and -K3- may be pressed together.

Clutch -K1- must only be pressed off -K3- if one of the clutches is to be dismantled or renewed.

• ‒ Ensure the tool press surface is flat and not damaged.

The pin of tube 3110 faces to plate VW 402.

• ‒ → Hold turbine shaft when pressing off.

Pressing clutch -K1- onto -K3-

• ‒ Moisten O-ring with ATF.
• ‒ → Insert new O-ring in the recess in the turbine shaft (arrow).

• ‒ → Clip (2) axial needle bearing (1) with washer to 3rd and 4th gear clutch -K3-.

• ‒ Ensure the tool press surface is flat and not damaged.
• ‒ → Prepare -K1- and -K3- for pressing as illustrated.

• ‒ → Before pressing on, align VW 418 A centrally onto surface for axial needle bearing (this illustration shows -K3- from below).
• ‒ Press clutch -K1- on carefully until stop is perceptible.
• ‒ Do not exert further pressure onto clutches !

Assembling planetary gearbox

• ‒ → Fit O-ring into planet carrier.

After replacing planet carrier, adjust => Page 37-99.

• ‒ → Insert axial needle bearing with washers and planet carrier in the input gear.

1 - Input gear is installed in gearbox housing => Page 37-61.

2 - Axial needle bearing washer, insert smooth side into input gear.

3 - Axial needle bearing

4 - Axial needle bearing washer

5 - Install planet carrier with seal fitted

• ‒ → Place washer and axial needle bearing on the "small sun gear" in the planet carrier.
• ‒ Centralize washer and axial needle bearing in small sun gear.

• ‒ Install components of brake B1.
• ‒ Insert shim of correct thickness.

Up to 2 shims may be installed.

• ‒ Insert first outer plate.

• ‒ Insert remaining inner and outer -B1- plates.
• ‒ Insert pressure plate with flat side facing plates.

Thickness of pressure plate varies according to number of plates, replacement parts are allocated according to gearbox code letters.

• ‒ → Insert dished washer with convex facing towards freewheel.

When replacing

• ◆ Gearbox housing
• ◆ Freewheel
• ◆ Piston for reverse gear brake -B1-
• ◆ or plates

then adjust -B1-, => Page 37-108.

• ‒ → Preload freewheel rollers with assembly ring 3267 and insert free wheel.

• ‒ → Install circlip for freewheel -b- and circlip for supporting tube -a-.
• ‒ Insert circlip gaps over freewheel retaining wedge (arrow).
• ‒ Install gearbox speed sender -G38-.

=> Repair group 01; Electrical/electronic components and fitting locations

• ‒ Perform check measurement of -B1-
  => Page 37-115

• ‒ → Insert components into gearbox housing starting with the large sun wheel down to small input shaft.

1 - Large sun wheel

2 - Needle bearing washer

• (collar faces to large sun wheel)

3 - Axial needle bearing

4 - Large input shaft

5 - Axial needle bearing

6 - Needle bearing

7 - Small input shaft

• ‒ → Installing small drive shaft bolt -1- with washer -2- and shim -3-,
      Tightening torque 30 Nm.

• ◆ Insert shim -3- onto small input shaft shoulder (arrow).
• ◆ Determining shim thickness => adjusting planet carrier, Page 37-99.

• ‒ Perform planet carrier check measurement
  => Page 37-107.

• ‒ → Insert new O-ring in the recess in the turbine shaft (arrow).
• ‒ Moisten O-ring with ATF.

On some gearboxes the clutches -K1- and -K3- must be pressed together before installing.

• ‒ Check that clutch -K1- can be fitted completely onto turbine shaft splines of -K3-.
• ‒ Do this by fitting -K1- onto -K3- by hand.

• ‒ → If the splines -arrow 1- are visible in the -K1- hub, then both clutches must be pressed together first => Page 37-84.

→ If resistance of O-ring is overcome when connecting together (by hand!), then the spline -arrow 1- in -K1- is not visible.

In this case the clutches do not need to be pressed together.

• ‒ Continue to assemble the gearbox.

• ‒ → Clip axial needle bearing with thrust washer to 3rd and 4th gear clutch -K3-.

1 - Axial needle bearing with thrust washer

• Moisten axial needle bearing washer with ATF so that the bearing, when installing sticks to -K3-. Insert bearing washer on -K3-.

2 - 3rd and 4th gear clutch -K3-

• ‒ → Ensure piston rings seat correctly on -K3-.
• ‒ Ensure that the ends of the piston rings are hooked together.

• ‒ → Inserting 3rd and 4th gear clutch -K3-.
• ‒ Fit seal -1- in the groove (arrow).
• ‒ Moisten O-ring with ATF.

• ‒ → Inserting 1st to 3rd gear clutch -K1-.

If -K1- and -K3- are pressed together, both clutches can only be inserted together.

• ‒ → Insert shims -arrow- in -K1-.

• ◆ Remeasure shim when replacing -K1-, -K2- or ATF pump => adjusting clutch play between -K1- and -K2-, Page 37-116.
• ◆ 1 or 2 shims can be installed.

• ‒ → Inserting reverse gear clutch -K2-.
• ‒ Insert supporting tube for -B2- plate set (arrow) so that supporting tube groove engages in freewheel wedge.

• ‒ → Install -B2- plates as follows:
• ‒ First insert a 3 mm thick outer plate
• ‒ Insert three spring caps in outer plate
• ‒ Insert compression springs (arrows)
• ‒ Insert all, but the last outer plate
• ‒ Insert three spring caps onto compression springs.

The brake play -B2- is determined by the thickness of the last outer plate only on gearbox versions having a corrugated spring washer. Determining thickness of plate is described on => Page 37-135.

• ‒ Insert last -measured- outer plate.
• ‒ Install corrugated washer

→ On all other gearboxes (with retaining ring -b-) the last outer plate is always 3 mm thick. The clearance of brake -B2- is determined by a shim -a-, on which the retaining ring -b- seats. A corrugated spring washer is not present.

• ‒ Insert last outer plate -3 mm thick-.

Determine shim => Page 37-124.

• ‒ Install shim.
• ‒ Insert retaining ring -b- onto shim. Smooth side facing shim.

When replacing

• ◆ the gearbox housing
• ◆ Supporting tube
• ◆ the ATF pump
• ◆ corrugated spring washer
• ◆ retaining ring
• ◆ or the plates

then the 2nd and 4th gear brakes -B2- are to be adjusted,

=> Page 37-124.

These components are allocated as replacement parts according to gearbox code letters.

• ‒ Install ATF pump seal.
• ‒ Fit O-ring on ATF pump..
• ‒ → Install ATF pump.
• ‒ Tighten bolts evenly, crosswise.

Ensure that the O-ring is not damaged.

Tightening torque: 8 Nm.

• ‒ Then turn bolts 90 ° further.

• Turning further can be done in several stages.

• ‒ Carry out check measurement of clutch play => Page 37-123.
• ‒ → Insert sealing plugs with O-rings.

• Installation position: Lug engages in oil channel.

• ‒ Install valve body with conductor strip => from Page 38-24.
• ‒ Install sump => from Page 38-24.
• ‒ Install cover with gasket and spacer bushes.

• ‒ → Install ATF overflow pipe -1- and level plug -2-.
• ‒ Install torque converter.
• ‒ Install gearbox => Page 37-25.
• ‒ Fill with 3 litres of ATF => Page 37-47.