6-Speed Manual Gearbox

Service
Workshop Manual
Córdoba 2003 ➤
Ibiza 2002 ➤
0A8 6-speed manual gearbox
Edition 05.2009
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
Córdoba 2003 ➤ , Ibiza 2002 ➤
0A8 6-speed manual gearbox - Edition 05.2009
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Codes, engine allocation, gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Filling amounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Overview of the drive force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Calculation of the gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Clutch mechanism: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Pedal mechanism, clutch pump - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Remove and install bearing bracket and master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Removing and installing clutch pedal switch F36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Over-centre spring: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.5 Clutch pedal: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.6 Clutch hydraulic system: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Clutch release assembly, clutch slave cylinder: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Clutch release assembly, slave cylinder - Installation overview . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Clutch slave cylinder: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Pipe and hose assembly: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4 Clutch system: bleeding of air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.5 Input shaft oil seal: replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 Clutch: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1 Clutch: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2 Clutch: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1 Gear mechanism: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 Shifting: installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2 Gear stick handle with cover - Installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3 Removing / fitting the gear lever knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.4 Gear lever cover: removing the knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.5 Gear selection mechanism:installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.6 Gear selection mechanism: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.7 Selector lever control cable - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.8 Gear drive mechanism: adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2 Gearbox : removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.1 Gearbox : removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2 Transporting and securing gearbox to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Gearbox oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.1 Check and refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.2 replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.3 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4 Gearbox: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.1 Gearbox: Component overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.2 Gearbox: installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.3 Gear box and shaft. Installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.4 Drive shaft, drive shafts (drive shafts), differential gear and gear prongs of the gearbox -
installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.5 Gearbox, switching activity, main shaft, secondary shaft (drive shaft), differential and shift
forks remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5 Gearbox casing: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Contents i
5.1 Gearbox housing - installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

5.2 Gearbox casing: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6 Clutch housing: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.1 Clutch housing - installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.2 Clutch housing: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7 Gear selection mechanism (gearbox side) removing and fitting . . . . . . . . . . . . . . . . . . . . 85
7.1 Gear selection mechanism:installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.2 Seal gear selection mechanism - replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8 Gearbox prongs: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.1 Selector forks - installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.2 Gear prongs: Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1 Disassembly and assembly of the input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.1 Input shaft - Installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.2 Disassembly and assembly of the input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2 Secondary shaft for 1st to 4th gear: disassembly and assembly . . . . . . . . . . . . . . . . . . . . 96
2.1 Secondary shaft for 1stª to 4thª gear - installation overview . . . . . . . . . . . . . . . . . . . . . . . . 96
2.2 Secondary shaft for 1st to 4th gear: disassembly and assembly . . . . . . . . . . . . . . . . . . . . 98
3 Secondary shaft for 1st to 4th gear: adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4 Secondary shaft for 5th/6th and reverse gear: disassembly and assembly . . . . . . . . . . . . 111
4.1 Secondary shaft for 5th/6th and reverse gear - installation overview . . . . . . . . . . . . . . . . . . 111
4.2 Secondary shaft for 5th/6th and reverse gear: disassembly and assembly . . . . . . . . . . . . 112
5 Secondary shaft for 5th/6th and reverse gear: adjustment . . . . . . . . . . . . . . . . . . . . . . . . 119
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

1 Seals for flanged shafts: replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.1 Seal for flanged shaft, left hand side: changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.2 Right flanged shaft seal: replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2 Adjustment chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3 Differential: assembly and disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.1 Differential: installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.2 Differential: assembly and disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3.3 Differential: Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4 Equivalence table according to applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.1 Graphic information on SEAT equivalent tools and equipment . . . . . . . . . . . . . . . . . . . . . . 140
ii Contents
00 – Technical data
1 Gearbox identification
Location on the gearbox
The 0A8 6-speed manual gearbox for front wheel drive is fitted in
the Ibiza 2002 > and Cordoba 2003 > together with the 1.9L TDI
engine, 96 kW, 110 kW or 118 kW. Allocation ⇒ page 1 .
Engine code and date of manufacture -arrow-
0A8 manual gearbox -arrow 2-.
0A8 Manual gearbox
Identification letters and manufacture date of gearbox -arrow-

Example: FUP 04 09 2
I I I I
Identification Day Month Year of manufac‐
letters ture (2002)
Any additional data is related to the manufacturing process.
1.1 Codes, engine allocation, gear ratios

6-speed manual gear‐ 0A8 6 speed
box
Identifica‐ FSM, FJW HDS, JNC, GUC JNF JSA, KDW,
tion letters JRX, KDV, KPC
KPB, KYA
Corre‐ Model Ibiza 2002 >, Ibiza 2002 >, Ibiza 2002 >
spond‐ Córdoba 2003 Córdoba 2003
ence > >
Engine 1.9 TDI -96 kW 1.9 TDI -96 kW 1.9 TDI - 118 1.9 TDI - 96 kW 1.9 TDI - 118
kW 118 kW kW
110 KW
96 kW
Ratio Final 65 : 22 = 2,955 68 : 21 = 3,238 65 : 22 = 2,9551)
group 1 1) 1)
1. Gearbox identification 1
6-speed manual gear‐ 0A8 6 speed

box
Identifica‐ FSM, FJW HDS, JNC, GUC JNF JSA, KDW,
tion letters JRX, KDV, KPC
KPB, KYA
Z2 :Z1=i Final 65 : 27 = 2,407 68 : 26 = 2,615 65 : 27 = 2,4072)
group 2 2) 2)
1. Road 49 : 13 = 49 : 13 = 47 : 14 = 3,3571
speed 3,7691 3,7691
2. Road 48 : 23 = 48 : 23 = 48 : 23 = 2,0871
speed 2,0871 2,0871
3. Road 45 : 34 = 45 : 34 = 47 : 32 = 1,4691
speed 1,3241 1,3241
4. Road 41 : 45 = 42 : 43 = 37 : 34 = 1,0881
speed 0,9111 0,9771
5. Road 37 : 41 = 39 : 40 = 41 : 37 = 1,1082
speed 0,9022 0,9752
6. Road 34 : 45 = 35 : 43 = 31 : 34 = 0,9122
speed 0,7562 0,8142
speed in 13 x 23 : 13 x 23 : 14 x 23 :
reverse
1) Drive shaft mechanism from the 1st to the 4th gear
2) Drive shaft mechanism from the 5th to the 6th gear and reverse gear
1.2 Filling amounts

Identifica‐ FSM, FJW HDS, JNC, GUC, JNF,
tion let‐ JRX, KDV, JSA , KDW,
ters KPB, KYA KPC
Filling quantity 2.3 litres 2.3 litres 2.3 litres
Specification Gear oil⇒ Parts catalogue SAE 70 W 75
(synthetic)
Clutch action Hydraulic
Clutch plate ∅ 240 mm 240 mm 240 mm
Drive shaft flange ∅ 113/75,5 mm 113/75,5 mm 113/75,5 mm
itotal.in top gear 1,819 2,128 2,195
2 Rep. Gr.00 - Technical data

2 Overview of the drive force

Gear ratios
Note
The -arrows- indicate direction of movement.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft (main shaft)
5 - Secondary shaft for 5ª/6ª
and reverse gear (drive shaft
II)
6 - Secondary shaft for 1ª to 4ª
gear (drive shaft I)
7 - Differential:
I - 1. gear
II - 2. gear
III - 3. gear
IV - 4. gear
V - 5. gear
VI - 6. gear
R - speed in reverse
A - Final group
2.1 Calculation of the gear ratio “i”

The gear ratio between two gears, is obtained by dividing the
number of teeth on the driven gear (Z2), by the number of teeth
on the driving gear (Z1).
Example:
0A8 6-speed manual 6a gear Final group
gearbox
Driving gear ZG1 = 45 ZA1 = 27
Driven gear ZG2 = 34 ZA2 = 65
2. Overview of the drive force 3

i = Z2 : Z1 Z1 = Number of teeth of driver pinion,

Z2 = Number of teeth of driver pinion
iG = Gear ratio = ZG2 : ZG1 = 34 : 45
= 0,756
iA = axle ratio = ZA2 : ZA1 = 65 : 27
= 2,407
iges = Total gear ratio = iG x iA = 0,756 x 2,407
= 1,819

3 General repair instructions

For proper repair of the gearbox, it is important to work with the
greatest of care and absolute cleanliness, and to use tools that
are in perfect condition. Naturally, the customary basic safety
rules must be observed during repair work.
A series of general instructions for repair work is now listed, and
these are mentioned several times throughout the course of the
Repair Manual. These instructions are valid for this Repair Man‐
ual,
Contact corrosion
♦ The gearbox casing is made of magnesium alloy.
♦ The surfaces of the bolts and other parts which are in direct
contact with the gearbox are made of a material which is es‐
pecially suitable for the magnesium casing.
♦ If inappropriate parts are used (bolts, nuts, washers...), corro‐
sion will be produced through contact and the gearbox casing
will be damaged.
♦ If you are doubtful as to whether it is possible to re-use certain
parts, it is advisable to fit new ones⇒ Current parts catalogue.
WARNING
♦ Only use genuine Seat parts!

♦ Damage from contact corrosion is not covered under the
warranty!
Gearbox:
♦ Thoroughly clean unions and adjacent areas before removing.
♦ Select the correct bolts and other components ⇒ Parts cata‐
logue .
♦ When installing the manual gearbox, ensure that the dowel
sleeves are correctly housed between engine and gearbox.
♦ When installing support stands and waxed components, the
contact surfaces must be cleaned. The contact surfaces must
be free from wax and grease.
♦ After replacing the gearbox, check oil level and top up if nec‐
essary.
♦ Filling amounts and oil type specifications.
3. General repair instructions 5

O-rings, seals, gaskets

♦ O-rings, seals and gaskets must always be replaced.
♦ After removing gaskets, check that the contact surfaces of the
casing and shaft do not show feathering or damage caused by
the removal process.
♦ Before fitting radial seals, apply a little oil to their outer perim‐
eters and fill the space between the sealing lips -arrow-, to half-
way, with sealant grease ⇒ Parts catalogue .
♦ The open side of the flanges must point towards the liquid to
be sealed.
♦ Fit the new flange in such a way that its sealing lip is not seated
in the same place as the lip of the previous flange (taking ad‐
vantage of the tolerance in the housing depth).
♦ Before fitting O-rings, lightly lubricate them so that they are not
flattened during installation.
♦ Check oil level after replacing flanges and gaskets.
Sealant
♦ Thoroughly clean contact surfaces of the casing before apply‐
ing sealant to them.
♦ Apply the sealing paste uniformly, in a layer which is not too
thick ⇒ Parts catalogue .
♦ Sealant must not enter the vent holes.

Safety locks
♦ Replace safety rings.
♦ Do not over-expand safety rings.
♦ The securing rings must be perfectly seated in their groove.
♦ Replace split pins. Installation position: the groove -A- is posi‐
tioned lengthwise to the flow of the pressure -arrow-.
Bolts, nuts
♦ Loosen bolts and nuts in reverse of tightening sequence.
♦ The bolts and nuts to be used to secure covers and casings
must be released and tightened diagonally in stages when no
tightening order is specified.
♦ Always replace self-locking nuts and bolts.
♦ The torque settings refer to non-oiled nuts and bolts.
♦ Threaded holes where there had been self-locking bolts or
bolts with thread fixing agent must first be cleaned (for exam‐
ple, with a threading male). If this is not done, the bolts may
break when removed again.
♦ In all bolted unions, ensure that supporting surfaces and bolts
and nuts are only waxed after installation, if this is necessary.
Bearings
♦ Install new roller bearings as supplied (without additional oil‐
ing).
♦ All bearings (apart from roller bearings) of the gearbox must
be fitted lubricated with gear oil.
♦ Before fitting interior rings of roller bearings, first heat them to
100 ºC approx. Use the electric blower -SAT 1416- . When
installing, they must be pressed in to their limit, without leaving
axial play or rebound.
♦ The temperature can be measured with the digital thermom‐
eter -SAT 4002- .
♦ Do not confuse the outside and inside rings of the bearing with
the rings from other bearings of the same size.
♦ Roller bearings fitted into one same shaft must be replaced
together, using products of the same manufacturer.
♦ Position gear needle roller bearings with the stamped side
(thicker plate) towards the mandrel to be fitted.
Shims
♦ Check shim settings at various points, using a micrometer.
The existence of different tolerances allows the necessary
shim thickness to be selected exactly.
♦ Check for burrs and damages. Install only perfect shims.
Synchromesh rings
♦ Must not be swapped. Do not mix up synchroniser rings from
different gears.
♦ Check for wear and replace if necessary.
♦ Fit them lubricated with gear oil.
Gears
♦ Before fitting pinions, they must be cleaned and heated to 100
ºC approx. Use the electric blower -SAT 1416- .
3. General repair instructions 7

♦ The temperature can be measured with the digital thermom‐

eter -SAT 4002- .
mobile pinion
♦ Check whether, after fitting, the mobile pinions of 1st ª to 6thª
gear have slight axial play and move easily.
Clutch action
♦ When removing the gearbox, the clutch slave cylinder must be
extracted without opening the piping system.
♦ If the clutch slave cylinder is removed together with the hy‐
draulic pipe, do not press the clutch pedal. Otherwise, the
slave cylinder piston will be expelled.
♦ Do not incline the pressure disk; loosen slightly in each pas‐
sage and diagonally, the installation is done in the same way.
♦ To reduce the unpleasant smells of a burnt clutch, the clutch
bell-housing must be thoroughly cleaned, along with the fly‐
wheel and engine at the side facing the clutch.
Extraction of the outer roller bearing rings and the bearing bushes
using the kit -T20140-
• Remove the outer rings of the conical roller bearings or the
bearing bushes as follows:
– Measure (if possible) the internal diameter of the external ring
of the roller bearing or the bearing bush.
– Select the appropriate clamp from the kit -T20140- noting the
following:
• If the diameter measured is less than 30 mm:
– Fit the valve tappet for small clips /10 and the appropriate clip
for internal diameters.
• If the diameter measured is greater than 30 mm:
– Fit the valve tappet /28 with the clip /29 and the appropriate
grips for internal diameters.
– Screw nut /5 and washer onto the valve tappet.
– Place the tool on the outer ring of the roller bearing or the
bearing bush and fit the threaded legs so that they are firmly
secured.
• The legs of the bridge /1 have different sized recesses

-arrows- to support on surfaces of different levels, rims or ribs.
– Adjust the screw feet of the bridge so that the bridge is parallel
to the bearing allotment surface or bush and extract it.
– Open the clamps until the bar is housed below the exterior
roller bearing or the bearing bush.
– Operate the extractor until the outer ring of the conical roller
bearing or bearing bush is extracted.
Note
In certain cases the space where the hooks must be fitted is min‐
imum, an initial extraction must be carried out to partially remove
the bearing bush, then, the hooks are re-adjusted the maximum
possible to achieve a larger contact surface. Then, continue with
the extraction of the bearing or the bush.

30 – Clutch
1 Clutch mechanism: repairs
1.1 Pedal mechanism, clutch pump - Assembly overview
1 - Securing panel
❑ Attachment for the mas‐
ter cylinder and the
clutch pedal mount
2 - Seal
❑ Always replace.
3 - Support stand
❑ For housing the clutch
pedal
4 - Bolt
5 - Mounting rack for pedal
work
❑ For accommodation of
the brake and accelera‐
tor pedals
6 - -25 Nm self-locking hexag‐
onal nut
❑ Always replace.
7 - Clutch pedal switch
❑ Press the clutch pedal
down for removal and
fitting of the switch
❑ For removal, rotate it
90º to the left and re‐
move it from its allot‐
ment
❑ Fit the clutch pedal
switch into mount and
turn 90º to right.
8 - Separation cap
9 - Bearing bush
10 - Clutch pedal
❑ removing and fitting ⇒ page 16
11 - Mounting
❑ Removing and installing
12 - 25 Nm self-locking hexagonal nuts
❑ Always replace.
13 - Clutch master cylinder
14 - Flexible hose
15 - Over-centre spring
1. Clutch mechanism: repairs 9

16 - Over-centre spring seat

❑ Install in pedal bracket
17 - Bolt
❑ To secure the clutch pedal stop on the pedal bracket
18 - Clutch pedal stop
19 - -25 Nm self-locking hexagonal nut
❑ Always replace.
1.2 Remove and install bearing bracket and

master cylinder
Check the tool and equipment equivalence table according to the
applicability between Seat / VW / Audi / Skoda ⇒ page 138 .
Special tools and workshop

equipment required
♦ Circuit clamp (female) -SAT
1210- , see equivalent
⇒ page 138
♦ Circuit clamp (male) -SAT
⇒ page 138
♦ Torque wrench kit -SAT
⇒ page 138
♦ Pliers -T20029- , see equiv‐
alent ⇒ page 138
♦ Hose clamp -U 30042- , see
equivalent ⇒ page 140
10 Rep. Gr.30 - Clutch

Note
♦ Brake fluid is toxic. It should not come into contact with the
paintwork due to its corrosive effects.
♦ When handling the brake fluid hoses, place a large protective
cover or cloth with no loose threads under the clutch master
cylinder.
♦ Always replace bolts and gaskets.
♦ The clutch master cylinder is removed from the interior of the
vehicle.
1.2.1 Removing
For those vehicles with an anti-theft code radio, the code must be
found before removing the battery.
– Disconnect earth wire at battery with ignition switched off.
– Remove engine cover.⇒ Maintenance ; Booklet 2
– Remove air filter housing; gasoline engines ⇒ Rep. Gr. 24
and diesel engines ⇒ Rep. Gr. 23 .
– Clamp the return hose -A- with the clamp -U 30042- .
– Carefully extract the hose -A- going to the brake fluid tank.
– Using screwdriver -1-, remove retaining clip -B- that holds pipe
and hose -C-to the clutch master cylinder.

– When removing the hose on the master cylinder side, use the
clutch circuit clamp (female) -SAT 1210- for the hose and the
clutch circuit clamp (male) -SAT 1211- of the master cylinder.
– Remove the lower trim of the driver's side footwell ⇒ Interior
body work; Rep. Gr. 68 ; Stowage compartment, coverings
and trims .
– Remove clutch pedal ⇒ page 16 .
– Remove the bolt -arrow- securing the clutch pedal stop to the
pedal bracket, according to the description.
– Remove the hexagonal nuts -arrows- and extract the pedal

bracket -1- from the front panel.
– Remove the master cylinder from the front panel.
1.2.2 Installation
– Installation is carried out in the reverse sequence; note the
following:

Note
Lubricate the end of the tappet with lubricating grease, according

to ⇒ Parts catalogue.
– Fit the clutch master cylinder to the front panel.

– Connect the pedal bracket to the base of the dashboard and
secure with its nuts.
– Install clutch pedal .
The allotment -A- must be on the operating rod -B- of the clutch
master cylinder.
– Secure the piston rod and, at the same time, press on the
clutch pedal in the direction of the -arrow- to insert it into its
allotment, ensure that it is correctly inserted on the clutch ped‐
al.
Note
If necessary, to aid the fitting of the connection on the clutch ped‐

al, loosen the bolt securing the pedal to its bracket; this will allow
more axial play between the pedal and the support.
– Tighten hexagonal nut with collar: always replace: Starting

torque: 25 Nm.
– Insert clutch pedal switch into mount and turn 90º to right.
– Fit the bolt -arrow- securing the clutch pedal stop to the pedal
bracket.

Note
Replace the O-rings.
– Press in pipe and hose assembly -1- with new O-ring -2- in
master cylinder connection -4- until securing clip -3- is audibly
secured.
– Pull pipe and hose assembly to check it is properly secured.
– Bleed air from hydraulic clutch system ⇒ page 26 .
1.3 Removing and installing clutch pedal

switch -F36-
So that it is correctly fitted in the clutch pedal bracket, the clutch
pedal switch -F36- should only be fitted once.
1.3.1 Removing
– Remove the shelf compartment from the driver's side ⇒ Body‐
work-Fitting work, interior; Rep. Gr. 68 ; Stowage compart‐
ments, covers and trim .
– Pull out -1- from the clutch pedal switch -F36-
– Rotate the clutch pedal switch -F36- -2- 45° to the left and pull
it out of the position.
Note
The clutch pedal remains in rest position, that is, not pressed.
1.3.2 Assembly and adjustment

– Before fitting the clutch pedal switch -F36- the entire rod must
be removed -3-.
• The pedal -4- must be in rest position.
– Insert the clutch pedal switch -F36- through the installation
hole, pressing it against the clutch pedal and securing it by
rotating 45° to the right.
– Plug in the connector of the clutch pedal switch -F36- .
– Fit the shelf compartment on the driver's side ⇒ Bodywork-
Fitting work, interior; Rep. Gr. 68 ; Stowage compartments,
covers and trim .

1.4 Over-centre spring: removing and fitting

Special tools and workshop equipment required
♦ Pliers -T20059B- , see equivalent ⇒ page 138
1.4.1 Removing
and trims .
– Remove the clutch pedal switch from its allotment by turning
it 90º to the left and separating it.
Release the clutch pedal from the operating rod of the master
cylinder as described below:
– Place the pliers -T20059B- in the notches on the clutch pedal.
– Squeeze the allotment using the pliers -T20059B- to release
the clutch pedal.
– Clutch pedal in the highest position (toward bulkhead) so that
the over centre spring is almost free of tension. Press the
spring unit easily and take it out. Ensure on the right seat of
the spring that the spring does not loosen on the bearing ped‐
estal
1.4.2 Installation
– Move the clutch pedal to the highest position, to the dash‐
board.
– Place the over-centre spring in its seating, next to the clutch
pedal bracket.
– Lightly squeeze the spring assembly and sit it on the clutch
pedal.
– Secure the clutch pedal to the operating rod of the control cyl‐
inder as described below:

– The allotment -A- must be on the operating rod -B- of the clutch
master cylinder.
– Fasten actuation rod -B- and press clutch pedal in
-direction of arrow- into mount. Ensure that the actuation rod
is seated correctly in clutch pedal.
– Sometimes, in order to fit the allotment it is necessary to re‐
move the securing nut from the clutch pedal and gently move
the attachment screw on the pedal bracket to give the clutch
pedal greater axial clearance.
– Tighten the nut.
1.5 Clutch pedal: removing and fitting

♦ Torque wrench kit -SAT 8010- , see equivalent ⇒ page 138
♦ Pliers -T20059B- , see equivalent ⇒ page 138
Note
♦ If the vehicle is fitted with a coded radio (anti-theft code), check

the code before removing the battery earth strap.
♦ Before removing the clutch pedal, extract the switch from its
allotment by rotating it 90º to the right and pulling it out.
♦ Press the clutch pedal down for removal and fitting of the
switch.

1.5.1 Removing
and trims .
– Before removing the clutch pedal, extract the switch from its
allotment by rotating it 90º to the left and pulling it out of its
seat.
– Release the clutch pedal from the operating rod of the master
cylinder as described below:
– Place the pliers -T20059B- in the notches on the clutch pedal.
– Squeeze the allotment using the pliers -T20059B- to release
the clutch pedal.
– Remove the over-centre spring ⇒ page 15 .
– Unscrew the nut -A-, always replace this.

In order to extract the clutch pedal bolt, partially loosen the nuts
securing the pedal support to the bodywork.
– Extract the bolt that joins the clutch pedal to the pedal bracket
and remove the clutch pedal together with the bearing socket.
1.5.2 Installation
Installation is carried out in the reverse sequence; note the fol‐
lowing:
– Fit the clutch pedal to the bracket with the bolt and the bearing
bushing.
– Fit the nut and its washer.
– Fit the over-centre spring ⇒ page 15 .
– Connect the clutch pedal to the master cylinder operation rod.
The allotment -A- must be on the operating rod -B- of the clutch
master cylinder.
– Press the clutch pedal-in the direction- of the arrow in its re‐
cording. Ensure that the actuation rod is seated correctly in
clutch pedal.
– Sometimes, in order to fit the allotment it is necessary to re‐
move the securing nut from the clutch pedal and gently move
the fastening screw on the pedal bracket to give the clutch
pedal greater axial clearance.
– Tighten the nut.

1.6 Clutch hydraulic system: assembly overview
1 - Brake fluid reservoir

2 - Circulation hose
3 - Clutch master cylinder
❑ removing and fitting
⇒ page 10
4 - Mounting
❑ Replace only with the
clutch master cylinder
removed
❑ Removing ⇒ page 19
❑ Installing ⇒ page 19 .
5 - Clutch pedal
6 - 25 Nm self-locking hexago‐
nal nut
❑ Always replace.
7 - Sealing ring
❑ Always replace.
8 - Pipe and hose assembly
❑ With frequency modula‐
tor
❑ Consult the parts cata‐
logue for its allocation
9 - Support
❑ Fixed onto the body‐
work
10 - Sealing ring
❑ Always replace.
11 - Bleeding equipment
12 - Sealing ring
❑ Always replace.
13 - Clip
14 - Bleeder valve
❑ Purging the clutch system ⇒ page 26 .
15 - Protective cap
16 - Clip
17 - Clutch slave cylinder
18 - Clip

Remove allotment -A- by levering in the direction of the arrow
Install the clutch master cylinder operating rod in the allotment

-A-, in the direction of the arrow
Removing and installing pipe and hose assembly on the air bleed‐
er valve
– To remove, release the securing clip -2- with a screwdriver and
disconnect the hose -4-from the air bleeder valve -1-.
Note
When removing the hose assembly for the slave or master cylin‐
der, use the hydraulic seal clamps to avoid liquid leaking onto the
bodywork.
– For installation a new O-ring -3- must be fitted to the slave

cylinder. Insert the air bleeder valve into the slave cylinder
connection until the attachment clip is connected with an au‐
dible click.
– Pull on the air bleeder valve to ensure that it is correctly se‐
cured.

Removing and fitting the air bleeder valve on the slave cylinder
– To remove, the release the safety fastener -2- with a screw‐
driver then unscrew and disconnect the air bleeder valve -4-
from the slave cylinder -1-.
– For installation a new O-ring -3- must be fitted to the slave
cylinder. Insert the air bleeder valve into the slave cylinder
connection until the attachment clip is connected with an au‐
dible click.

2 Clutch release assembly, clutch

slave cylinder: repairs
2.1 Clutch release assembly, slave cylinder - Installation overview
1 - Gearbox:
2 - Input shaft oil seal:
❑ Changing
3 - Clutch slave cylinder with
clutch release collar
❑ This unit may not be re‐
placed separately
❑ Do not wash out the
bearing. Wipe it only
with a cloth
❑ Change the collar along
with the slave cylinder if
they make too much
noise
4 - Screw, 12 Nm
❑ 3 pieces
5 - O-ring
❑ Fit in the tube connec‐
tion
❑ Fit with brake fluid
2.2 Clutch slave cylinder: removing and in‐

stalling
2. Clutch release assembly, clutch slave cylinder: repairs 21

♦ Circuit clamp (male) -SAT 1211- , see equivalent

⇒ page 138
2.2.1 Removing
Note
♦ The slave cylinder and the clutch release collar make up one
unit and may only be replaced together.
♦ When performing the following operations, care must be taken
not to spill brake fluid onto the side member or gearbox. If fluid
comes into contact with them, the affected area must be thor‐
oughly cleaned.
♦ When carrying out work on the footwell compartment, the car‐
pet must be protected from brake fluid spillage with cloths.
♦ When removing the hose assembly or master cylinder, use the
hydraulic seal adapters to avoid liquid leaking onto the body.
For those vehicles with an anti-theft code radio, the code must be
found before removing the battery.
– Remove the battery and the battery support: ⇒ Electrical sys‐
tem; Rep. Gr. 27 ; Battery; Battery: removing and fitting.

– Release the securing clip -2- with a screwdriver then discon‐

nect the air bleeder valve -4- from the slave cylinder -1-.
– Connect the clutch circuit clamp (male) -SAT 1211- to the air
purge valve.
– Remove gearbox.
– Screw out bolts -arrows-.

– Remove the slave cylinder with the collar -A-.
2.2.2 Installation
Installation is carried out in reverse order, noting the following:
Note
Renew O-ring.
– Securely tighten the slave cylinder with the collar.

– Fit a new O-ring -3- to the slave cylinder.
– Insert the air bleeder valve into the slave cylinder connection
until the attachment clip is connected with an audible click.
– Pull on the air bleeder valve to ensure that it is correctly se‐
cured.
– Install gearbox .
– Bleed air from the clutch system
2.3 Pipe and hose assembly: removing and

fitting

♦ Hose clamp -U 30042- , see equivalent ⇒ page 140
♦ Pliers -T20029- , see equivalent ⇒ page 138
2.3.1 Removing
– Remove the engine sound insulation cover, pulling upwards
-arrows A- and forwards -arrow B-.
– Press the spring-type clamp -1- with pliers -T20029- and re‐
move the hose from the air filter assembly.
– Release the hose -2- and connector -3- from the air filter unit.
– Remove the conduct -4- from the air filter.
– Unscrew the screws -5- attaching the air filter in the battery
holder: Torque: 8 Nm.
– Pull the air filter assembly upwards gently to extract it.
– Remove the battery ⇒ Electrical system; Rep. Gr. 27 ; Bat‐
tery .

– Unscrew the bolts -arrows- and remove battery bracket.
Note
♦ The slave cylinder and the clutch release collar make up one
unit and may only be replaced together.
not to spill brake fluid onto the side member or gearbox. If fluid
comes into contact with them, the affected area must be thor‐
oughly cleaned.
♦ When carrying out work on the footwell compartment, the car‐
pet must be protected from brake fluid spillage with cloths.
♦ When removing the hose assembly or master cylinder, use the
hydraulic seal adapters to avoid liquid leaking onto the body.
– Choke the input hose going to the master cylinder with the
pressure tool -U 30042- .
WARNING
Do not press on the clutch pedal following the removal of the

pipe and hose assembly.
– Remove pipe and hose assembly from master cylinder.

– Using screwdriver -1-, remove retaining clip -B- that holds pipe
and hose -C-to the clutch master cylinder.

– Remove pipe and hose assembly from air bleeder valve.

– To remove, release the securing clip -2- with a screwdriver and
disconnect the hose -4-from the air bleeder valve -1-.
– Release the pipe and hose assembly from mounting.
2.3.2 Installation
Installation is carried out in reverse order, noting the following:
Note
Replace the O-rings.
– Press in pipe and hose assembly -1- with new O-ring -2- in
master cylinder connection -4- until securing clip -3- is audibly
secured.
– Press in pipe and hose assembly -4- with new O-ring -3- on
the bleeder valve connection -1- until securing clip -2- is au‐
dibly secured.

– Bleed air from hydraulic clutch system ⇒ page 26
– Fit the battery ⇒ Electrical system; Rep. Gr. 27 .
2.4 Clutch system: bleeding of air


♦ Brake bleeder -SAT 1175B- , see equivalent ⇒ page 138
Note
♦ After carrying out work on the hydraulic clutch mechanism, the

system must be bled.
not to spill brake fluid onto the longitudinal member or gearbox.
♦ Before bleeding the brake fluid tank must be filled to the “max”
mark.
♦ Brake fluid specification ⇒ Brake system; Rep. Gr. 47 .
2.4.1 Procedure:
– Remove the engine sound insulation cover, pulling upwards
-arrows A- and forwards -arrow B-.
– Press the spring-type clamp -1- with pliers -T20029- and re‐
move the hose from the air filter assembly.
– Release the hose -2- and connector -3- from the air filter unit.
– Remove the conduct -4- from the air filter.
– Unscrew the screws -5- attaching the air filter in the battery
holder: Torque: 8 Nm.
– Pull the air filter assembly upwards gently to extract it.
– Remove the battery ⇒ Electrical system; Rep. Gr. 27 ; Bat‐
tery .

– Unscrew the bolts -arrows- and remove battery bracket.

– Return clutch pedal to park position.
– Connect brake bleeder -SAT 1175B- to brake fluid reservoir,
but do not start.
– Remove protection hood on brake bleeder bolt -arrow- and

connect hose -A- of air bleeding bottle to this bolt.
– Now start up air bleeding apparatus.
• Working pressure: 2.0 bar, positive pressure
– Open air bleeding screw with the tube of the air bleed bottle
attached and let it bleed some 100 cm3 of brake fluid.
– Close the bolt on the air bleeder element.
– Quickly operate pedal from limit to limit 15 times.
– Open air bleeding element bolt and bleed another 50 cm 3 of
brake fluid.
– Tighten the bolt on the air bleeder element 4.5 Nm.
– Once the air bleeding operation is completed, operate the
clutch pedal several times.
– Bleed the system once more if necessary.
– Remove the bleed hose and fit the protection hood.
– Remove brake bleeder -SAT 1175B- from brake fluid reser‐
voir.
2.5 Input shaft oil seal: replacement

♦ Push rod -T20130- , see equivalent ⇒ page 138

♦ Extractor kit -T20143- , see equivalent ⇒ page 139
♦ Lubricating grease ⇒ Parts Catalogue
2.5.1 Procedure:
– Remove gearbox ⇒ page 47 .
– Remove the clutch slave cylinder with the release collar
⇒ page 21 .
– Remove input shaft seal by levering with extractor -T20143/1- .
Note
Do not damage contact surface for input shaft seal.
– Fill space between sealing lip and dustcap -arrow-, halfway,

with sealing grease ⇒ Parts catalogue .
– Fit seal flush with installation tool -T20130-

– Fit the clutch slave cylinder with the release collar.
⇒ page 21 .
– Install gearbox ⇒ page 47 .

3 Clutch: repairing
3.1 Clutch: assembly overview
Note
♦ Gearbox removed.
♦ Before replacement of the clutch disk and the clutch press, a test must be made to decide whether the fault
is originating from the clutch release assembly or the operation mechanism.
♦ Always replace any clutch plates and clutch presses with damaged or loose rivet joints.
♦ Ensure correspondence of the clutch disk and clutch press according to the spare parts catalogue and the
engine identification letters.
1 - Flywheel
❑ Check that the centring
pins are correctly seat‐
ed
❑ The contact surface of
the clutch disk must not
have any grooves and
must be free of oil or
grease
❑ Remove and install ⇒
Rep.-Gr. 13; flange and
flywheel / driving disc re‐
move and install
2 - Clutch plate
❑ Bore
❑ The shortest lining
-arrow- faces the clutch
press
❑ Centering ⇒ page 31
❑ Lightly lubricate the
splines
Note
3 - Clutch press
⇒ page 31
❑ Check the ends of the
diaphragm ⇒ page 31
Note
4 - Screw, 13 Nm
❑ Consult the parts cata‐
logue for its allocation
❑ Dual mass flywheel, Tightening torque 13 Nm
❑ Always replace.
❑ Loosen and tighten diagonally several times

Checking the ends of the diaphragm

• The wear limit is up to half the thickness of the edges of the
diaphragm -Arrows-
Check flexible connection and riveted unions

– Check flexible connection between pressure disk and cover
for cracks and check that riveted unions are correctly seated.
– Replace clutches with damaged springs or loose riveted un‐
ions -arrows-.
3.2 Clutch: removing and installing

3. Clutch: repairing 31

equipment required
⇒ page 138
♦ Hose clamp -T20176- , see
♦ Push rod -U 10050-10- ,
see equivalent
⇒ page 139
♦ Lubricating grease ⇒ Parts
Catalogue .
3.2.1 Removing
– Apply counterhold -T20176- to slacken bolts of pressure plate.
– Slightly slacken bolts diagonally at each stage.
– Remove pressure disk and clutch plate.
3.2.2 Installation
• Installation is carried out in the reverse order of removing,
when doing this note the following.

Note
♦ Replace clutch plate and pressure disk with damaged or loose

riveted unions.
♦ To reduce the unpleasant smells of a burnt clutch, the clutch
bell-housing must be thoroughly cleaned, along with the fly‐
wheel and engine at the side facing the clutch.
♦ Allocate clutch plate and pressure disk according to engine
code ⇒ Current parts catalogue .
♦ Eliminate any corrosion from the input shaft teeth and the disk
hub of the clutch, applying a fine layer of approved lubricating
grease ⇒ Parts catalogue . Then move the clutch plate on the
input shaft from side to side, until the hub moves smoothly on
the shaft. It is essential to remove excess grease.
♦ The pressure disk has anti-corrosion protection and is
greased. Only the contact surface must be cleaned; otherwise
the working life of the clutch will be considerably reduced.
♦ The contact surface of the pressure disk and clutch plate lining
must be in total contact with the flywheel. Only then can the
securing bolts be inserted.
• Clutch plate installation position: the spring cage should point

towards the pressure plate.
– When installing clutch assembly, place counterhold -T20176- .
– To centre the clutch plate, use the centring guide -U 10050/A-
with the adaptor -U 10050/T- .
– Only slightly tighten bolts diagonally in stages, so as to avoid
damaging centring holes of pressure disk and centring pins of
flywheel. Tightening torque ⇒ Item 4 (page 30) .
3. Clutch: repairing 33
34 – Controls, housing
1 Gear mechanism: repairing
1.1 Shifting: installation position

Gear movement -arrow A-
-Arrow B-: movement for gear track selection
A - Connection cable for gear

engagement
B - Selection control cable for
selecting tracks
C - Heat shield
❑ Must be removed before
the gear drive mecha‐
nism is removed
1 - Gear selection rod
2 - Return lever
Note
♦ To carry out work on the gear operation mechanism in the engine compartment, the battery earth strap must
be disconnected.
♦ For vehicles fitted with an anti-theft code radio, the code must be found first.
Gear selection mechanism: removing and fitting ⇒ page 40 .

Adjust the gear selection mechanism ⇒ page 44 .
34 Rep. Gr.34 - Controls, housing

I - Gear stick handle with cover:

Installation overview
⇒ page 36
II - Shifting: Installation over‐
view ⇒ page 39
III - Selector lever control ca‐
ble: Installation overview
⇒ page 43
1. Gear mechanism: repairing 35

1.2 Gear stick handle with cover - Installation overview
1 - Gear lever knob

❑ Removing and fitting
with cover ⇒ page 36
❑ Separating and assem‐
bling the knob
⇒ page 37
2 - Cover
❑ Separating from gear
knob ⇒ Fig.
⇒ page 37
❑ Secure to the knob be‐
fore fitting
❑ Remove and fit along
with the gear lever knob
3 - Attachment bush
❑ Join the cover with the
gear lever knob
❑ removing ⇒ page 37
4 - Fastening clamp
❑ To hold knob onto gear
lever
1.3 Removing / fitting the gear lever knob

and cover
♦ Pliers -T20072A- , see equivalent ⇒ page 138

1.3.1 Removing
– Remove the central console cover ⇒ Rep. Gr. 68 .
Note
The gear lever knob is removed together with the gear lever cov‐
er.
– Open tightening clamp -arrow- and remove knob with gear

lever cover.
1.3.2 Installation
Installation is carried out in the reverse order of removing, when
doing this note the following.
– Fit knob with cover, as far as they will go, onto gear lever.
– Secure gear lever knob with a new tightening clamp using the
pliers -T20072A- .
Note
Pay special attention to the measurement of the handle assembly

tightening clamp, -A = 4 ± 0.2 mm-.
1.4 Gear lever cover: removing the knob
1.4.1 Removing
– Removing the gear selector handle ⇒ page 36 .
– Turn dust cover over.

– Open the securing tabs using a screwdriver -arrow- and ex‐

tract the knob.
1.4.2 Assembly:
– Insert the knob onto the dustguard.
– Press clamping sleeve onto shift lever knob and arrest.
Note
The bushing tabs must be fitted into the knob allotments.

1.5 Gear selection mechanism:installation overview
Note
Lubricate the support points and contact surfaces with polycarbamide grease ⇒ Parts catalogue .
1 - Securing washer
⇒ page 40
2 - Bush
3 - Compression spring
4 - Bush
5 - Torx screw 5 Nm
6 - Plug
7 - Bearings
8 - Damper
9 - Gear lever guide
10 - Damping ring
11 - Seal
❑ Between protection
housing and floor
❑ Self-adhesive
❑ Stick it onto the protec‐
tive cover
12 - Gear stick
13 - Hexagon nut, 25 Nm
14 - Threaded pins
15 - Damper
16 - Lever protection box
17 - Bearing bush
18 - Support pin
19 - Guide sleeve
20 - Compression spring
❑ Installation ⇒ page 40
21 - Selector bracket
22 - Torx screw 5 Nm
23 - Lower plate
❑ To disassemble, open the tabs
❑ replace
24 - Securing washer
25 - Selection control cable
❑ Connects to the selector bracket
❑ Installation position ⇒ page 34

26 - Gearchange control cable

❑ Fit into the gear lever guide
27 - Bearing bush
❑ Fits in only one position
Removing and installing securing washer

– To remove and install securing washers, pull the gearshift lev‐
er in the direction of arrow -arrow A-, and at the same time
press downwards on the spacer bush with a screwdriver in the
direction of arrow -arrow A- all the way.
Note
♦ Do not tilt the spacer when pressing it. Access must be avail‐
able to the groove in the gear lever where the securing ring is
seated. Loosen the spring carefully.
♦ The groove in the gear lever where the securing ring is seated
must be in sight.
♦ Loosen the compression spring.
Fitting compression spring

– Install the spring so that end -A- is above the pivot -arrow-.
– Pull end -B- downwards until it fits into the bottom of the pivot
-arrow-.
1.6 Gear selection mechanism: removing

and fitting
1.6.1 Removing

– Pull forwards, in the direction of the cable securing mechanism

-arrow 1-, from the gear selection and engagement, rotating it
after to the left in the direction of the -arrow 2- to secure it, and
separate the cables from the securing elements.
– Remove the cables from the support, releasing the securing
rings carefully to avoid damaging them.
– Extract the cables from the support on the side of the gearbox.
– Remove the central console cover.
– Lightly press on the front of the cover -arrow-, and rotate par‐
tially towards the upper part for removal.
To remove the gear lever cover, open the clamp and remove the
gear lever knob along with the cover ⇒ page 36 .
– Extract the nuts that support the protective housing -arrows-.

– Separate the floor protection lining, lower part.
– Remove the brackets -1- . Torque: 25 Nm.

– Loosen exhaust system from double clamp -2-.
– Loosen the exhaust tube from the front part -arrows- of the
subframe.
– Remove heat insulation.-3-
– Release the gear lever casing from the body structure.
– Remove the protective housing of the gear-shift and rotate to‐
gether with the lines. When doing this, do not damage me‐
chanical parts and body.
1.6.2 Installation
Installation is carried out in the reverse sequence; note the fol‐
lowing:

– Apply a small amount of polycarbamide grease in the securing

element casting of the gear shift cable -A-, and selector cable
-B-.
– Fit the cables in the securing elements, rotate all the way the
securing mechanism of the shift and selection cables to the
right -arrow-.
The spring returns the safety mechanism to the initial position.
– Adjust the gear selection mechanism ⇒ page 44 .
– Install exhaust system and align without strain ⇒ Rep. Gr. 26 ;
Exhaust system .
– Fit the battery ⇒ Electrical system; Rep. Gr. 27 ; Battery .

1.7 Selector lever control cable - Assembly overview
Note
Lubricate the support points and contact surfaces with polycarbamide grease ⇒ Parts catalogue .
1 - Gearchange control cable

❑ Fit into the gear lever
guide
❑ Installation position
⇒ page 34
2 - Selection control cable
❑ Connected to the relay
lever
⇒ page 34
3 - Securing washer
4 - Securing washer
❑ Do not damage the ca‐
bles when removing
5 - Lever protection box
6 - Counter support
7 - Elastic pin
❑ For counter support on
the gearbox
8 - Separator
9 - 25 Nm hexagonal bolt
❑ For counter support
10 - Cable attachment
❑ For selection control ca‐
ble in idler lever
❑ Always replace when
the relay lever is re‐
moved
11 - Cable attachment
❑ To secure selection
control cable to relay lever
❑ Always replace when the relay lever is removed
13 - Bearing bush
14 - Return lever
❑ installation position
15 - Runner
16 - Selection pole with a counterweight
❑ Position so that the interrupted division of the teeth is adjusted to the selector rod
❑ Once fitted, adjust the gear operation mechanism ⇒ page 44 .
❑ installation position

17 - Hexagon nut, 25 Nm
❑ With washer
❑ Always replace.
Installation position of the link rod/selector lever

1 - Selection rod with counter weight
2 - Return lever
Operates by guide runner on the gear lever track -arrow-.
1.8 Gear drive mechanism: adjustment

♦ Hose clamp -T10027- , see equivalent ⇒ page 138
Note
♦ For the proper adjustment of the gearbox, the following points

are essential:
♦ Drive and transmission elements of the gear drive mechanism
in perfect condition.
♦ Gear operation mechanism works smoothly.
♦ In addition, the gearbox, the clutch and the clutch mechanism,
must be in perfect condition.
• Gearbox in neutral.
Note
To perform these tasks, the battery earth strap must be removed.

The vehicle should be checked for a fitted radio. If necessary ob‐
tain radio anti-theft code first.


– Pull the cable securing mechanism forwards, in the direction
of the -arrow 1-, from the gear selection and engagement all
the way, rotating it then to the left in the direction of the
-arrow 2- to secure it.
– Secure the gear selection shaft as follows:

– Press the selection shaft down -1- in the direction of the
-arrow-.
– At the same time as pressing on the selector lever -1-, insert
the retention pin -A- in the direction of the -arrow- until the shaft
is locked.
Note
In this position, the inner end of the retention pin -A- is inserted in
the selector lever holding it in the adjustment position.
The gear lever protection cover should come out of the centre
console.
– Remove the centre console cover, carefully moving it towards
the upper part.
– Place the gearshift lever in neutral position and secure it as
follows:
– Insert the Retention tool -T10027- into the hole -B- through the
hole -A-.
Note
To facilitate the fitting of the retention tool -T10027- , move the

gear lever so that the two holes are aligned.

– Rotate all the way the securing mechanism of the shift and
selection cables to the right -arrow-.
– Pull the retention pin -A- in the direction of the arrow until it is
back in the initial position.
– Remove the retention tool -T10027- and fit the gear lever cover
to the centre console.
Verifying the gearbox operation mechanism
The gear lever must be in neutral, in the track for 3rd/4th gear.
– Press the clutch pedal, engage all gears several times. Above
all, ensure that the reverse gear lock is functioning properly
If, following the repeated engagement, the gears 1, 2, 5 or 6 con‐
tinue to present some difficulty, verify the following:
– Carefully move the selector lever from the neutral position to
the left into the 1st and 2nd gear tracks.
– Press the selection shaft down -1- in the direction of the

-arrow-.
If the gear selection mechanism is correctly adjusted, the reten‐
tion pin -A- may now be inserted into the gears (in the direction
of the arrow) as well as into the selector lever guide (using the
help of another mechanic).
If not, adjust the gear change mechanism ⇒ page 44 .

2 Gearbox : removing and fitting
2.1 Gearbox : removing and fitting


equipment required
♦ Hydraulic jack -SAT 1040- ,
see equivalent
⇒ page 138
⇒ page 138
♦ Gearbox support -
T20138C- , see equivalent
⇒ page 139
♦ Base -T20145- , see equiv‐
alent ⇒ page 139
♦ Bracket -U 30025E- , see
2. Gearbox : removing and fitting 47

♦ Circuit clamp (female) -SAT 1210- , see equivalent

⇒ page 138
♦ Circuit clamp (male) -SAT 1211- , see equivalent
⇒ page 138
2.1.1 Removing
– Disonnect the battery earth strap.
Note
Observe the measures to be adopted when disconnecting the

battery ⇒ Rep. Gr. 27 .
Note
For vehicles fitted with a coded radio, first check the anti-theft
code

Note
Note the relay lever shaft bushes.
– Remove the securing washer -A- and the gear engagement

cable from the relay/connection lever.
– Extract the securing washer -arrow 1- from the relay lever and
remove the assembly with the cable -B- from the selector lever
cover.
– Remove gear selector/engagement rod; to do this, the nut
must be unscrewed -arrow 2-.

– Unbolt the cable support from gearbox -arrows-.

– Position the cable assembly and lever so that they do not in‐
terfere with the subsequent operations.
– Unplug connector from speed sender -arrow-.
– Unplug connector from the starter motor -1-.

– Extract the connector for reverse lights arrow -2-.
– Rotate the upper mounting bolt from the starter. -3-.
– Disconnect the hook -4- all the way, and remove the hose.
– Seal off the pressure conduits of the clutch circuit using the
clutch circuit seal (male) -SAT 1211- on the side of the clutch
slave cylinder, and using the clutch circuit seal (female) -SAT
1210- on the side of the clutch master cylinder.
WARNING
Do not depress clutch pedal after removing slave cylinder.
Note
♦ When handling the brake fluid hoses, place a large protective
cover or cloth with no loose threads under the clutch slave
cylinder adaptor.

– Remove the earth cable from the upper gearbox to engine at‐
tachment bolt.
– Remove the upper bolts joining the engine and the gearbox.
– Separate the hoses and cables that may be in the area of the
engine where the rings that grip the support -U 30025E- go.
Note
♦ Ensure that the pipe connections and the cables in the area
where the engine is suspended do not suffer any damage
while fitting the hooks of the support equipment.
♦ When placing support -U 30025E- , ensure that the support
struts remain well seated in the profile of the wing and the bar
of the tool. Find the centre of the mechanical unit without dam‐
aging the bodywork.
– Put some force on the drive train using the spindles.

– Turn the wheels left.
– Remove front left-hand wheel.
– Remove left-hand side wheel well.
Note
There is no need to empty the coolant during the following oper‐

ation.
– Bring the lock carrier into service position ⇒ Rep. -Gr. 50; Body
- Installation outside: Lock carrier
– Remove the thermal protection plate from the right hand side
drive shaft.
– Disconnect the drive shafts from the flanged axles and secure
them as high as possible so that they do not impede the fol‐
lowing operations.
Before removing the bolts, mark the fitting positions with respect
to the strut.

– Extract the bolts -1- on the left hand side securing the ball joint
to the strut.
– Separate the two ends of the link rod -2- from the stabilizer
-arrow- and rotate the two ends towards the bodywork.
– Remove the pendulum support on the gearbox side extracting

the bolts -1-.
– Remove the pendulum support on the bridge side, extracting
the bolt -2-. Always replace torque: 40 Nm + 90°.
– Unscrew lower starter motor fixing bolt and remove starter
motor.
– Loosen the bolts of the double clamp -1- and release the sus‐
pension elements -arrows-.
– Unscrew gear holder. Turn the mounting screws-1- from the

console.
– Partially lower the drive train to unhook the gearbox attach‐
ment bracket and extract the bolts -2-.
– Extract the bolts -3- securing the bracket to the bodywork, and
separate the bracket assembly.

– Remove the small protection plate -A- for the engine flywheel.
– Extract the conical securing bolt from the right hand side
flanged shaft; screw in two bolts onto the flange and lock the
shaft with the help of an assembly lever.
– Affix the gear on the gearbox bracket -T20138C- to the support

-T20145- and to the Engine-/ gear jack -SAT 1040-
– Extract the gearbox/engine lower securing bolts, disengage
gearbox from guide sleeves.
– Regulate the base -T20145- so that gearbox moves without
force on the rigid drive shaft, at the same time separating
gearbox from engine.
Note
Do not damage power steering lines and coolant lines when low‐
ering gearbox.
2.1.2 Installation
Note
♦ Clean the splines on the input shaft and lightly lubricate them
with grease ⇒ Spare Parts Catalogue .
♦ It must be possible to move the clutch plate from side to side
on the input shaft.
♦ Check whether dowel sleeves for centring the engine/gearbox
assembly are fitted in the cylinder block; install if necessary.
♦ Ensure that the intermediate plate is correctly seated on the
engine.
♦ Note the power steering lines and the clutch mechanism.
– The fitting of the gearbox is carried out in the reverse order of

removal operations.
In order to install the gear it must be on the bracket -T20138C- on
the gear box -T20145- and this must be attached on the engine/
gear jack -SAT 1040-
For the coupling of the gearbox to the engine, the knob of the gear
holder -T20138C- must be operable in order for the gearbox to
align with the pods.
– Before completely closing the gearbox, fit the right hand side
flanged axle. Include gear with the corresponding screws: Tor‐
que ⇒ page 54 .

– Fit the left hand side console with the bolts -2- to the gearbox,
before lifting the entire drive train.
– Fit the gearbox bracket to the bodywork, secure the console
and gear change mechanism with the bolts -1-.
– Position the drive train assembly so that the bolts -3- align on
the bodywork.
Note
Once the drive train brackets are fitted, tighten with no strain.
– Fit the stabilizer bar by the two ends.

– Fit the drive shafts to the gearbox ⇒ Running gear, axles,
steering, front wheel drive; Rep. Gr. 40 ; Articulated drive
shafts :
– Install exhaust system⇒ Rep. -Gr. 26; Remove and install the
parts of the exhaust system .
– Fit the starter motor and secure it with the lower bolt.
Note
♦ When handling the fluid lines, place a large protective cover
or cloth with no loose threads under the clutch slave cylinder
adaptor.
– Remove the clutch circuit clamp (female) -SAT 1210- and the
clutch circuit clamp (male) -SAT 1211- from the lines and the
clutch slave cylinder.
– Fit the hoses and secure with the hook -4-.

– Fit the upper securing bolt -3- of the starter motor.
– Connect the starter motor connectors -1- as well as that for the
reverse gear light -2-.

2.1.3 Torque settings

Gearbox on the engine:
Item Bolt Nm
1 ,2
3) 4) 3) 4)
M12×55 80
3 3), 4 3) M12×165 80
5 4) M12×105 80
6 4), 7 4) M10×50 40
8 4) M10×70 40
3) M8 threaded bolt
4) Replace bolt
A - dowel sleeves for centring
– Bring the lock carrier into service position ⇒ Rep. -Gr. 50; Body
- Installation outside: Lock carrier
– Fit the battery bracket.
– Fit the battery ⇒ Electrical system; Rep. Gr. 27 ; Battery .
– Connect the earth strap to the battery.
Note
If the vehicle comes with an anti-theft code radio, find the code.
– Check the gear oil ⇒ page 57 .

– Bleed air from hydraulic clutch system, if necessary
⇒ page 26 .
– Adjust the gear selection mechanism ⇒ page 44 .
– Fit engine cover ⇒ Maintenance ; Booklet 2 .

2.2 Transporting and securing gearbox to assembly stand


equipment required
♦ Base -T20172/1- , see
♦ Tower -T20172/2- , see
♦ Gearbox support -
T20172/4A- , see equiva‐
lent ⇒ page 139
♦ Counterhold -T20186- , see
Procedure:
– Fit the base -T20172/1- with the tower -T20172/2- and the
gearbox support -T20172/4A- .
– Fit counterhold -T20186- on gearbox in order to transport it.

– Fit the gearbox to the gearbox support -T20172/4A- as shown

in the figure.

3 Gearbox oil level


♦ Wrench -T20118- , see equivalent ⇒ page 138
♦ Tray -T20173- , see equivalent ⇒ page 139
3.1 Check and refill

– Raise the vehicle.
3. Gearbox oil level 57

– Vehicles with diesel engine: Unscrew bolts - 1 … 3- and re‐

move center noise insulation.
– Vehicles with diesel engine: Unscrew bolts -1- … -2- and re‐
– Loosen oil level test bolt -arrow-.
Note
Oil level is correct when the oil reaches the bottom edge of filling
hole.
Oil specification for gears ⇒ page 2 .

– If the oil level is not correct, complete oil level.
– Unscrew control lid, start engine and let the gears work with
engaged gear for about 2 minutes.
– Stop the engine, remove oil cap and check level again, top up
if necessary.
– Screw the oil level control lid and tighten with the appropriate
torque ⇒ page 60 .
– Install the middle soundproofing.
3.2 replace
– Raise the vehicle.

– Vehicles with diesel engine: Unscrew bolts - 1 … 3- and re‐

– Vehicles with diesel engine: Unscrew bolts -1- … -2- and re‐
– Place below the collecting tray -T20173- .
– Unscrew drain plug -arrow- and empty gearbox oil.
– Unscrew oil level test and filler plug -arrow-.

– Screw the oil release control lid and tighten with the appropri‐
ate torque ⇒ page 60 .
Note
Oil level is correct when the oil reaches the bottom edge of filling
hole.
Oil specification for gears ⇒ page 2 .

– Fill with new gear oil up to the correct level.
– Unscrew control lid, start engine and let the gears work with
engaged gear for about 2 minutes.
– Stop the engine, remove oil cap and check level again, top up
if necessary.
– Screw the oil level and filling control lid and tighten with the
appropriate torque ⇒ page 60 .
– Install the middle soundproofing.
3. Gearbox oil level 59

3.3 Torque settings

Component Nm
Grooved interior head nut -I- for plugging oil fill‐ 45
er/change hole.
Allen bolt -II- for plugging oil filler/change hole 30

4 Gearbox: disassembly and assembly
4.1 Gearbox: Component overview
1 - clutch housing
2 - Reverse gear shaft:
3 - Secondary shaft for 5th/6th
and reverse gear
4 - Clutch slave cylinder with
clutch release collar
5 - Input shaft:
gear
7 - Differential:
8 - Insert shaft
9 - Articulation flange
10 - 2nd speed selector gear
11 - 1st speed selector gear
12 - 4th gear wheel
13 - 3rd speed selector gear
14 - 5th gear wheel
15 - 6th speed selector gear
16 - Mobile pinion of reverse
gear
17 - Gearbox
4. Gearbox: disassembly and assembly 61

4.2 Gearbox: installation overview
l - Gearbox housing and gear

selection shaft - assembly
overview ⇒ page 64
ll - Input shaft, secondary shaft
(drive), differential gear and
gearbox forks - assembly over‐
view ⇒ page 64

4.3 Gear box and shaft. Installation overview
1 - 25 Nm conical bolt
⇒ page 123
3 - Cover
4 - Circlip
5 - Reverse light switch, -20
Nm
6 - Sealing ring
❑ replace
7 - Empty plug for Oil
❑ Allen screw, -30 Nm
❑ Bolt with internal
grooved head - 45 Nm
8 - Sealing ring
❑ replace
9 - Locking bolt for the selec‐
tion shaft - 30 Nm
10 - Bolt - 15 Nm and tighten
90° (1/4 turn) further
❑ With secured washer
❑ replace
11 - Bolt - 15 Nm and tighten
90° (1/4 turn) further
❑ Without washer
❑ replace
12 - Gear selection mecha‐
nism
❑ Disassembling and as‐
sembling the heating system ⇒ page 85
❑ Remove with the gearbox fitted:
– Remove the battery and its support.
– Remove the control cables and the selection rod
– Unscrew the locking bolt and pull out the gearbox operation mechanism
13 - Screw, 20 Nm
❑ replace
14 - O ring
❑ replace
15 - clutch housing
❑ Repairing ⇒ page 80
16 - Gearbox
❑ Repairing ⇒ page 73

4.4 Drive shaft, drive shafts (drive shafts), differential gear and gear prongs of
the gearbox - installation overview

gear
sembling the heating
system ⇒ page 98
⇒ page 65
2 - Control rod with prongs for
1stª and 2ndª gear
⇒ page 65
3 - Selector rod with selector
fork for 3rd and 4th gear
⇒ page 65
and reverse gear
system ⇒ page 111
⇒ page 65
fork for 5th and 6th gear
⇒ page 65
6 - Reverse gear prong
⇒ page 65
7 - Input shaft:
system ⇒ page 92
❑ With thrust washer
9 - Attack washer
10 - Air bleeding valve
❑ Connect the clutch slave cylinder ⇒ Item 14 (page 64)
11 - clutch housing
13 - O ring
❑ replace
❑ Fit in the tube connection
❑ Apply brake fluid before fitting
14 - Clutch slave cylinder with clutch release collar
15 - Screw, 12 Nm
❑ 3 pieces
❑ replace

18 - Differential:
❑ Disassembling and assembling
Fitting position of the control shafts and rods in the gearbox

1 - Input shaft:
2 - Secondary shaft for 1ª to 4ª gear
3 - Secondary shaft for 5th/6th and reverse gear
A - Control rod with prongs for 3ª and 4ª gear
B - Control rod with prongs for 1ª and 2ª gear
C - Control rod with prongs for 5ª and 6ª gear
D - Reverse gear prong

4.5 Gearbox, switching activity, main shaft, secondary shaft (drive shaft), dif‐
ferential and shift forks remove and install

equipment required
⇒ page 138
♦ Push rod -T20130- , see
♦ Tray -T20173- , see equiv‐
alent ⇒ page 139

♦ Hot air blower -SAT 1416- ,

see equivalent
⇒ page 138
♦ Extractor kit -T20140- , see
♦ Kit (case) -U 40200A- , see
4.5.1 Removing
– Attach the gearbox to the stand ⇒ page 55 .
– Rotate the gearbox on the assembly frame so that the oil plug
bolt is downwards.
– Fit tray -T20173- beneath gearbox.
– Drain gearbox oil.
– Screw out bolts -arrows-.
– Remove the slave cylinder with the collar -A-.

– Extract input shaft seal by levering with extractor kit -T20143- .
Note
Do not damage contact surface for input shaft seal.

– Place the gearbox mechanism shaft in the neutral position; to

do this release the locking pin -arrow-.
– Unscrew the locking pin -2-.
– Remove the hollow bolts -3-.
– Extract the selector shaft -4- from the gearbox housing.
Note
Ignore -items. 1-.
– Remove the flanged shaft and insert shaft.
– Unscrew the bolts -B- securing the gearbox housing from the
clutch housing.
Note
One of the bolts -arrow- is located off the flanged joint. This is
fitted with a washer.

– Pierce the rubber seal cover for the centre using a screwdriver.
– Remove the rubber seal cover from the gearbox using the ex‐
tractor kit -T20140- .
– Remove the securing ring -C- from the ball bearing of the input
shaft as follows:
– Support one of the securing ring ends using a screwdriver
-A-.
– Release the other end of the securing ring from the ball bearing
groove -arrow- using a second screwdriver as a lever -B-.
– Continue to undo the securing ring with the screwdriver -B-.
– Unscrew bolts -A-.

– Heat the gearbox casing, at the input shaft ball bearing allot‐
ment, using the hot air blower -SAT 1416- for about 10 minutes
until a temperature of about 100 ºC.
– Secure the retention tool -U 40007- for the input shaft to the
gearbox housing.

– Remove the gearbox casing from the clutch housing -arrow-

using the tool -T20187- .
Note
If necessary, apply an assembly lever carefully to the edges of

the gearbox housing to undo it, changing from one side to another
without causing damage to the sealing surfaces.
Note
To remove the shafts from the clutch housing, a second mechanic

is required.
– Lift the differential gear -1- with the left hand.

– Use the right hand to lift the secondary shaft for the 1st to 4th
gears along with the control rod -2-, -arrow A-.
– At the same time, the second mechanic must remove the pri‐
mary, inverter and secondary shaft of the 5th/6th gears -3-,
along with the control rods, out of the clutch housing
-arrow B-.
Note
In case of doubt, the differential may rest on the clutch housing

after lifting the shafts.
– Release the input shaft oil seal ⇒ page 28 .
4.5.2 Installation
– Insert the input shaft -1- and the secondary shaft for the 5th/
6th and reverse gear -2-, along with the control rod -3-, the
prong -4- and inverter shaft -5-.

Note
To fit the shafts in the clutch housing, a second mechanic is re‐

quired.
– Fit the differential -1-.

– Use the right hand to hold the secondary shaft for the 1st to
4th gears -3- along with the control rods -4-, as shown in the
illustration.
– Lift the differential gear 1 with the left hand.
– At the same time, the second mechanic must lift the input shaft
and the secondary shaft for the 5th/6th and reverse gears-2-
along with the inverter shaft.
– Now insert the secondary shaft for the 1st to 4th gears in the
-direction of the arrow-.
• 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 into their seats.
– Secure the retention tool -U 40007- for the input shaft to the
gearbox housing.
Note
For clarity, the clutch housing appears rotated 180 º.
– Screw in the bolt -A- until the input shaft lifts a little.
– Heat the gearbox housing at the input shaft ball bearing allot‐
ment using the hot air blower -SAT 1416- for about 10 minutes
until reaching a temperature of about 100 ºC.
– Fit the gearbox housing.
– Fit the securing ring for the ball bearing of the input shaft.
– Remove retaining tool -U 40007- .
– If the insertion sleeve for the selection shaft was removed it

must be fitted using the mandril -T20188- to the limit of the tool
with the gearbox housing fitted.
– Rotate the gearbox on the assembly frame so that the opening
for the selection shaft is upwards.
– Insert the selection shaft -1- into the lower allotment -2- and
onto the prongs -3-.

Note
For clarity, the seal plug is removed.
– Press the selection rod -1- against the insertion sleeve -2-,
-arrow-, and lift it downwards using the finger -3-, by the
prongs, to the limit.
• While doing this, the selector lever mechanism cover -4-
should remain parallel to the surface where the gearbox hous‐
ing is bolted.
• The selection shaft should be easily moved upwards and
downwards (selection movement).
Note
If the selector lever mechanism cover is inclined relative to the

bolted surface, this means that the selection shaft is not inserted
in the lower allotment.
– Tighten the bolts -3- for the selector lever mechanism cover
-4-.
– Screw in the lock bolt -2-; to do this, the lock pin -arrow- must
be unscrewed.
– Screw in the reverse light switch -1-.
– Fit the flanged shaft and insert shaft.
– Fit the input shaft oil seal ⇒ page 28 .
– Fit the clutch slave cylinder with the release collar.
– Successively select all gears several times.
– Insert the seal plug, to the limit using the adapter -U 40200/16-
and the adapter -U 40200/10- , into the gearbox housing.

5 Gearbox casing: repairing
5.1 Gearbox housing - installation overview
Note
Mount gearbox on assembly stand ⇒ page 55 .
1 - Gearbox
❑ If this is replaced then
the ⇒ page 107 secon‐
dary shafts
⇒ page 119 and the dif‐
ferential ⇒ page 134
must be adjusted
2 - Cover
❑ Insertion ⇒ page 76
3 - Empty plug for Oil
4 - Sealing ring
❑ replace
5 - Oil filler plug
6 - Locking bolt
❑ Adjust gear selector
mechanism ⇒ page 44
❑ This may be replaced
with the gearbox without
disassembling
⇒ page 77
7 - Bearing sleeve for the con‐
trol rods
❑ Remove ⇒ page 77
8 - Insertion sleeve
❑ Remove with the gearbox disassembled
9 - Point crown for the inverter shaft
❑ Replace after removing
5. Gearbox casing: repairing 73

10 - Outer ring of roller bearing

❑ For secondary shaft for 5thª/6thª and reverse gear
❑ If replaced, the secondary shaft for 5thª/6thª and reverse gear must be readjusted ⇒ page 119
11 - Shim
❑ Adjustment chart ⇒ page 129
❑ For secondary shaft for 1stª to 4thª gear
❑ If replaced, the secondary shaft for 1stª/4thª gear must be readjusted ⇒ page 107
13 - Shim
❑ For the differential
❑ If replaced the differential must be replaced ⇒ page 134
15 - Shim
16 - Bearing socket for the selection shaft
❑ Remove
❑ Insertion
17 - Sealing plug
❑ Releasing
❑ Insertion
18 - Sealing ring
❑ replace
5.2 Gearbox casing: repairing



equipment required
♦
♦ Push rod -U 40204- , see


Remove the plug seal

– Pierce rubber in centre of sealing cap -A- with a screwdriver
-B- and pry off sealing cap -arrow-.
Insert the plug seal
Remove the locking pin for the selection shaft

– Release the pin, separating it in the release position.
– Insert a screwdriver -A- though the hole -B- of the locking pin.
– Unscrew the locking pin -arrow-.

Locking pin installation position

The mark -arrow- in the locking pin should point to the connection
-1- of the clutch slave cylinder.
The angle -a- should be about 45°.
Insert the locking pin for the selection shaft

• The locking pin -arrow- should be unlocked when it is inserted.
– Insert the locking pin until the limit of the tool.
Extract the bearing socket for the control rod

– Extract the bearing sockets using the adapter -T20129- and
the pressure tool -T20140/14- .
Insert the bearing sleeve for the control rod until it is flush
– Fit the sleeve with the end B of the installation tool -U 40204- .

Release the insertion sleeve with the gearbox disassembled us‐

ing the T20188
– Release the insertion sleeve using the installation tool -
T20188- using the lowest diameter.
• Locking bolt and the selection shaft are removed
– Rotate the gearbox so that the insertion sleeve does not fall
inside.
Insert the insertion sleeve with the gearbox assembled using the
T20188
• The gearbox housing is bolted to the clutch.
– Insert the insertion sleeve using the pressure tool -T20188- to
the limit of the tool using the largest diameter.
Extract the points crown for the shaft from the gearbox housing
– Extract the bearing sockets using the adapter -T20140/1- and
• The same disassembling process is used for both the gearbox
and the clutch housings
Insert the points crown for the inverter shaft into the gearbox
housing
– When inserting the thrust washer for the inverter shaft -B- must
be fitted onto the points crown -A-.
– Support the gearbox housing fitting the adapter -U 40200/20-
directly underneath the bearing allotment.

Extract the bearing socket for the selection shaft

– Extract the bearing bush for the selection rod using the pres‐
sure tool -T20129- and the kit (case) -U 40200A- .
Insert the bearing bush for the selection shaft

– Fit bearing socket -A- with installation tool -U 40204- .
Extract and insert the seal plug from the outside

– Release the seal plug from the outside with the tool -T20139-
using the lowest diameter.
– Insert the seal plug from the outside with the tool -T20139-
using the largest diameter.

6 Clutch housing:
6.1 Clutch housing - installation overview
1 - Bearing sleeve for the con‐

trol rods
2 - Reverse gear prong shaft
❑ This cannot be removed
using the workshop
tools
❑ Fit into the clutch hous‐
ing ⇒ page 84
3 - Point crown for the inverter
shaft
❑ Replace after removing
4 - Dowel sleeves
❑ 2 pieces
5 - clutch housing
❑ If this is replaced then
the ⇒ page 107 secon‐
dary shafts
⇒ page 119 and the dif‐
ferential ⇒ page 134
must be adjusted
❑ Replace ⇒ page 28
7 - Insert shaft oil seal
❑ replace
8 - Glass
❑ Installation position: the
interior diameter rebate should point towards the seal ⇒ Item 7 (page 80)
❑ If replaced the differential must be replaced ⇒ page 134
10 - Oil relay washer
❑ Installation position: the rebate of the hole should face towards the secondary shaft
❑ If replaced, the secondary shaft for 1stª/4thª gear must be readjusted ⇒ page 107


❑ If replaced, the secondary shaft for 5thª/6thª and reverse gear must be readjusted ⇒ page 119
13 - Glass
❑ 0.65 mm thick
14 - Cylindrical roller bearing
❑ For the input shaft.
15 - Magnet
❑ Supported by the separation surface of the housing
16 - Upper connector cover
6.2 Clutch housing:

6. Clutch housing: 81

equipment required
♦ extractor kit -T20143- , see
– Remove input shaft seal by levering with extractor -T20143/1- .



– Extract the bearing sockets using the adapter -T20140/14-
and the pressure tool -T20129- .

– Use the correct diameter according to the diameter of the
socket and insert to the limit.
Extract the point crown from the clutch housing

the extractor kit -T20140- .
Note
The point crown is damaged by removal and must always be re‐

placed.
– Extraction of the needle bearing.
Insert the point crown into the clutch housing

– When inserting the thrust washer for the inverter shaft -B- must
be fitted onto the points crown -A-.
6. Clutch housing: 83
Insert the reverse gear prong shaft into the clutch housing

7 Gear selection mechanism (gearbox

side) removing and fitting
7.1 Gear selection mechanism:installation

overview
Note
Lubricate the support points and contact surfaces with sealing

grease ⇒ Parts catalogue .
1 - Bearing socket for the se‐

lection shaft
2 - Gear selector shaft
❑ With the gearbox opera‐
tion mechanism cover
❑ It can be removed and
fitted with the gearbox in
place on the vehicle
3 - O ring
❑ Put into the groove of
the gearbox mechanism
cover
❑ Fit with gear oil.
❑ replace
4 - Hood for gearbox breather
5 - Sealing ring
❑ Replace ⇒ page 85
6 - Screw, 20 Nm
7.2 Seal gear selection mechanism - re‐

placement
7. Gear selection mechanism (gearbox side) removing and fitting 85

♦ Extractor kit -T20143- , see equivalent ⇒ page 139
7.2.1 Procedure:
– Detach safety clip -2- and, applying pressure, extract idler rod
to one side -3-, removing it from its housing.
– Unscrew nut -4- and remove selector rod -1-.
– Remove seal by levering with extractor -T20143/1- .

– Insert with an tappet -T20153- .

Rest of installation is carried out in the reverse sequence, ob‐
serving the following:
Note
The selector rod may only be placed in one position.
– Fit the battery ⇒ Electrical system; Rep. Gr. 27 .
7. Gear selection mechanism (gearbox side) removing and fitting 87

8 Gearbox prongs: disassembly and

assembly
8.1 Selector forks - installation overview
1 - Absorbent rubber
❑ Removed and fitted on
the control rod by hand
2 - Control rod with prongs for
1stª and 2ndª gear
fork for 3rd and 4th gear
fork for 5th and 6th gear
5 - Reverse gear prong
6 - Ball sleeves
8.2 Gear prongs: Repairing



equipment required
Extract the ball socket from the reverse gear prong

– Use the adapter -T20140/20- and the pressure tool -T20129- .
8. Gearbox prongs: disassembly and assembly 89

Insert the ball socket for the reverse gear prong

– Use the adaptor -U 40200/3- .

35 – Gears, shafts
1 Disassembly and assembly of the in‐
put shaft
1.1 Input shaft - Installation overview
Note
♦ Fix gearbox to installation stand.

♦ Always consult technical data when installing new pinions .
♦ Fit all of the input shaft bearings with gear oil.
1 - Circlip
2 - Gearbox
3 - Circlip
❑ If the ball bearing
⇒ Item 4 (page 91)
and the input shaft
⇒ Item 6 (page 91) is
replaced then
⇒ page 94 must be re-
established
4 - Ball socket
5 - Sprocket of 5thª gear
❑ Releasing ⇒ page 93
groove -arrow- should
point to the ball bearing
6 - Input shaft:
❑ With pinion for 3rdª/4thª
and 6thª gear
7 - Cylindrical roller bearing
❑ Circlip
securing ring should be
facing towards the input
shaft
8 - clutch housing
1. Disassembly and assembly of the input shaft 91

1.2 Disassembly and assembly of the input

shaft

equipment required
♦ Extractor kit -U 40100B- ,
see equivalent
⇒ page 140
92 Rep. Gr.35 - Gears, shafts

Extract the ball bearing

– Remove the input shaft securing ring.
– Before fitting the bridge with bolt -U 40100/1- first fit the adap‐
tor -U 40200/3- and the foot support flanges -U 40100/8- with
the cone base -U 40100/4- to the input shaft.
Release the 5thª gear pinion

– Place the flat base -U 40100/3- under the pinion for the 5th
gear
Insert the 5thª gear pinion

– Fit the input shaft in a vice with the pressure tool -T20141- and
insert the adaptor -U 40200/13- tools and the adaptor -U
40200/18- .

Insert the ball bearing

• Installation position: the groove for the securing ring should
point upwards and the rung should face towards the pinion of
the 5th gear
– Fit ball bearing with installation tool -U 40200/19-
– Determine the securing ring ⇒ page 94 and fit it.
Determining the correct securing ring

– Fit a securing ring -A- of 1.86 mm in thickness in the groove
of the input shaft and press upwards.
– Measure clearance between grooved ball bearing -B- and fit‐
ted circlip -A- using feeler gauge -C-.
– Remove the securing ring used for the measurement.
– Select the securing ring according to the table; part number ⇒
Parts catalogue .
The following securing rings are used:
Measured value Thickness of the se‐ Axial play (mm)
(mm) curing ring (mm)
0,01 … 0,05 1,86 0,01 … 0,05
0,05 … 0,07 1,89 0,01 … 0,05
0,07 … 0,10 1,92 0,01 … 0,05
0,10 … 0,13 1,95 0,01 … 0,05
0,13 … 0,16 1,98 0,01 … 0,05
Extract the roller bearing from the clutch housing

– To extract the roller bearings from the housing, press on the
securing ring using a pliers.

Extract the roller bearing from the clutch housing

– When pressing the arrow -on the backup ring- tapered roller
bearing with a -A- pair of pliers, squeeze the Adapter -U
40450/3- -U 40450/9-
– Remove the pliers before leaving the roller bearing in instal‐
lation position.
• The securing ring should insert into the groove of the clutch
pan.

2 Secondary shaft for 1st to 4th gear:

disassembly and assembly
2.1 Secondary shaft for 1stª to 4thª gear -

installation overview
Note

♦ If the secondary shaft or tapered roller bearings are replaced,
the secondary shaft must be adjusted. ⇒ page 119 .
♦ Whenever new meshes or a new secondary shaft are fitted
consult the technical data .
♦ Replace both conical roller bearings together.
1 - clutch housing
2 - Oil relay washer
3 - Dished washer
5 - Inner ring of roller bearing
gear
❑ Adjustment
⇒ page 107
7 - Needle bearing for the 3rd
gear
8 - 2nd speed selector gear
9 - Synchronizer ring (interior
ring of the 2ndª gear
❑ Check for wear
⇒ page 102
❑ Check that the tabs
show no signs of wear
⇒ page 103
10 - Outer ring for 2nd gear
❑ Replace this if there are
grooves or treads
caused by wear
❑ Fit to the synchro ring ⇒ Item 9 (page 96)

11 - Synchromesh ring of 2nd gear

❑ Check for wear ⇒ page 103
12 - Mobile sleeve/synchroniser body of the 1stª and 2ndª gear
❑ Release along with the 6th gear mobile pinion ⇒ Item 13 (page 97) after removing the securing ring
⇒ page 102
❑ Dismantling ⇒ page 103
❑ Assembling the mobile element/synchroniser body ⇒ page 103
❑ Insertion
13 - Circlip
14 - Synchromesh ring of 1st gear
❑ Fit so that the recesses insert in the locking parts of the mobile element. ⇒ Item 12 (page 97)
15 - Outer ring for 1st gear
❑ Replace this if there are grooves or treads caused by wear
16 - Synchronizer ring (interior ring of the 1stª gear)
❑ Check that the tabs show no signs of wear
17 - Needle bearing for the 1st gear
18 - 1st speed selector gear
19 - Thrust ring for the 1stª and 4thª gear
❑ 2 pieces
❑ Insert the thrust ring tab into the hole of the secondary shaft
20 - Glass
❑ Keep the thrust rings ⇒ Item 19 (page 97) in place on the secondary shaft
21 - Needle bearing for the 4th gear
22 - 4th gear wheel
23 - Syncromesh ring for 4th gear
24 - Mobile sleeve/synchroniser body of the 3rdª and 4thª gear
❑ After upgrading the locking ring ⇒ page 102 remove the gear 4ª with the rack wheel
❑ Installation position of the mobile element/synchroniser body. ⇒ page 103
❑ Assembling the mobile element/synchroniser body. ⇒ page 103 and ⇒ page 103
❑ inster ⇒ page 105
25 - Circlip
26 - Synchromesh ring of 3rdª gear
27 - Outer ring for 3rd gear
❑ Replace this if there are grooves or treads caused by wear
2. Secondary shaft for 1st to 4th gear: disassembly and assembly 97


28 - Synchronizer ring (interior ring of the 3rd gear)
❑ Check that the tabs show no signs of wear
29 - Needle bearing for the 3rdª gear
30 - 3rd speed selector gear
32 - Circlip
❑ When tapered roller bearing ⇒ Item 31 (page 98) or input shaft ⇒ Item 6 (page 96) are renewed: determine
thickness of required circlip ⇒ page 106
34 - Shim
❑ Determine thickness ⇒ page 107
35 - Gearbox
2.2 Secondary shaft for 1st to 4th gear: dis‐

assembly and assembly


equipment required
see equivalent
⇒ page 140

♦ Pliers -A 81124- , see

Extract the plate washer -A- from the secondary shaft

– Use the installation tool -T20099- .

Insert the plate washer -A- on the secondary shaft

– Insert the plate washer to the limit using the kit (case) -U
40200A- .
Extract the outer ring of the roller bearing from the gearbox casing
– Extract the outer ring of the conical roller bearing of the gear‐
box casing using the extractor kit -T20140- .
Insert the outer ring of the conical roller bearing from the gearbox
casing
– Press the clutch housing directly onto the support tool.
Release the inner ring of roller bearing

– Fit the bridge with bolt -U 40100/1- underneath the interior ring
of the conical roller bearings.
– Place the adapter -U 40200/1- between the pressure plate and
the drive shaft. Use the press.
Extract the mobile element/synchroniser body for the 3rd and 4th
gear along with the 4th gear mobile pinion
– Remove securing ring with pliers -A 81124- before this.
Extract the mobile element/synchroniser body for the 1st and 2nd
gear along with the 2nd mobile pinion
– Remove the securing ring.
– Place the bridge with bolt -U 40100/1- underneath the syn‐
chroniser for the 1st and 2nd gears, release the mobile pinion
and the mobile element/synchroniser body together.
Insert the inner ring of roller bearing

– Place the installation tool -U 40404- underneath the mobile
sleeve.
– Place the assembly inside a vice inserting the clamp -T20141-
and the adapter -U 40200/12- .
Check the wear of the inner ring of the 1st, 2nd and 3rd gear
– Press the inner ring against the mobile pinion cone and meas‐
ure the distance -a- with a thickness jig.
Dimension (a) Assembly level Wear limit

12., 3. Road speed 0,75 ... 1.25 mm 0,3 mm

Check the wear of the synchronization ring of the 1st, 2nd and 3rd
gear
– Press the synchromesh, outer and inner rings against the mo‐
bile pinion cone and measure the distance -a- with a thickness
gauge.

12., 3. Road speed 1,2...1,8 mm 0,5 mm
Installation position of the outer, inner and synchromesh rings for

2ndªgear
– Fit the interior ring -A- onto the mobile pinion for 2nd gear.
• The slanted reinforcements -arrows 1- should face the outer
ring -B-.
– Fit over the outer ring -B-.
• The tabs -arrows 2- insert into the recesses -arrows 3- of the
mobile pinion.
– Fit over the synchroniser ring -C-.
• The recesses -arrows 4- insert onto the protrusions
-arrows 1- of the inner ring -A-
Disassemble and assemble the mobile element/synchroniser

body for the 1st and 2nd or 3rd and 4th gear
– To disassemble, the springs must be removed -1-.
2 - Locking element
3 - Mobile element
4 - Synchromesh hub
– To assemble, fit the mobile element onto the synchroniser
body.
• Installation position: Narrower recesses in synchronising hub
align with recesses in locking collar
Assemble the mobile element/synchroniser body for the 1st and

2nd or 3rd and 4th gear
• Move the mobile element on the synchromesh body.
– Fit locking pieces and install springs offset by 120º.
• The protruding end of the spring should enter into the locking
element allotment.
Installation position of the mobile element/synchroniser body for

the 1st and 2nd gear
• The gullet -arrow 1- and the thin collar -arrow 2- of the syn‐
chroniser body should point to the 1st gear.
Insert mobile element/synchroniser body of the 1st and 2nd gear

– Then fit the securing ring.
Installation position of 1st and 3rd gear exterior ring

• The tabs -arrows- must point towards the mobile element/syn‐
chroniser body -A-.
Installation position of 1st and 3rd gear inner synchroniser ring

-A-.
• The tabs -arrows 1- insert into the recesses -arrows 2- of the
synchroniser ring-B-.

Installation position of the mobile pinion of 1st and 3rd gear

The highest collar -A- points towards the 2nd or 4th gear -B-. The
collar rebates -arrows- insert into the outer ring tabs.
Installation position of the mobile element/synchroniser body for

the 3rd and 4th gear
The widest collar of the synchroniser body -arrow- points towards
the 3rd gear.
Pressing on 3rd and 4th gear locking collar/synchronising hub

Check 4th gear synchroniser ring for wear.

– Press the inner ring against the mobile pinion cone and meas‐
ure the distance -a- with a thickness jig.

4 gear 1.0..0.10.7 mm 0,5 mm

– Operate the vice until the shaft securing ring can be fitted.

– Determine the thickest securing ring that can be fitted and
place it ⇒ Parts catalogue .
The following securing rings are used:
Thickness of the securing ring (mm)
1,79 1,83 1,86
1,89 1,92 1,95
1,98
Remove the outer ring of the roller bearing from the gearbox cas‐
ing
Fitting the outer ring of the roller bearing into the gearbox casing
– Fit a shim underneath the outer ring
– Support the gear housing directly under the outer ring allot‐
ment.

3 Secondary shaft for 1st to 4th gear:

adjustment
The secondary shaft should always be readjusted when any of
the following components have been changed:
♦ Gearbox
♦ clutch housing
♦ Secondary shaft for 1ª to 4ª gear
♦ Conical roller bearings

equipment required
⇒ page 138
♦ Bracket -T20020- , see
• The gearbox is secured on the assembly stand.

• The sealing surfaces of both the gearbox and the clutch should
be free of sealant.
• To carry out the measurement, only fit the shaft to be meas‐
ured.
3. Secondary shaft for 1st to 4th gear: adjustment 107

– Insert the roller bearing outer ring with a 1.70 mm shim into
the gearbox housing; to do this support the housing by fitting
the kit -U 40200A- underneath the bearing allotment.
– Insert the secondary shaft for the 1st to 4th gears into the
clutch housing.
– Fit the gearbox housing over and tighten the bolts -A- and
-B- diagonally with the correct tightening torque.

– Fit the support -T20020- and measurement tools securing

them to the clutch housing with the bolt -arrow-.
– Put the dial gauge (3 mm range) to “0” with a pretension of 1
mm.
– Loosen, diagonally, the bolts securing the clutch housing to
the gearbox until the gearbox housing or the secondary shaft
may be lifted.
– Read the value indicated by the dial gauge and note it (in the
example: 0.14 mm).
Note
When loosening the bolts securing the clutch housing to the gear‐
box, no value is indicated on the dial gauge, the shim of 1.95 mm
or that of 2.20 mm must be fitted to make the measurement.
Determining thickness of shim:

The specified bearing preload is attained by subtracting the meas‐
ured value (0.14 mm) from the inserted shim (1.70 mm) and
adding a constant value for preload (0.20 mm).
Example:
Shims fitted 1,70 mm
- measured value 0,14 mm
+ Pressure (const. value) 0,20 mm
Thickness of shim 1,76 mm
– Determine shim thickness using the table; part number ⇒
Current parts catalogue .
The following shims are used:
Thickness of shims 5) in mm
1,45 1,70 1,95 2,20
1,50 1,75 2,00 2,25
1,55 1,80 2,05
1,60 1,85 2,10
1,65 1,90 2,15
5) The existence of different tolerances allows the necessary shim thickness to
be selected precisely.
– Take off gearbox housing and pull tapered roller bearing out
of gearbox housing.
• Extraction of the outer roller bearing rings and the bearing
sockets using the extractor kit -T20140- .
– Remove the shim fitted (1.70 mm) from the gearbox housing.
3. Secondary shaft for 1st to 4th gear: adjustment 109

– Insert the roller bearing outer ring with the shim of the deter‐
mined thickness (in this case 1.75 mm) into the gearbox
housing; to do this support the housing directly underneath the
bearing allotment.
Measurement
• The required shim should already be fitted
mm.
may be lifted.
• The gauge should now be properly selected with levelling dosc
worth a value of 0.15 ... show 0.25 mm.

4 Secondary shaft for 5th/6th and re‐

verse gear: disassembly and assem‐
bly
4.1 Secondary shaft for 5th/6th and reverse

gear - installation overview
Note

♦ If the secondary shaft or tapered roller bearings are replaced,
the secondary shaft must be adjusted. ⇒ page 119
♦ Whenever new meshes or a new secondary shaft are fitted
consult the technical data .
1 - clutch housing
2 - Glass
❑ 0.65 mm thick
and reverse gear
❑ Adjustment
⇒ page 119
6 - Synchronizer body for the
reverse gear
⇒ page 115
7 - Circlip
8 - Connection guide for re‐
verse gear
❑ With synchronizing ring
9 - Bearing socket for the re‐
verse gear mobile pinion
10 - Mobile pinion of reverse
gear
11 - Sleeve
❑ Release from above the
reverse gear mobile pin‐
ion ⇒ page 114
❑ Installation position: the wide collar must point towards the reverse gear mobile pinion.
4. Secondary shaft for 5th/6th and reverse gear: disassembly and assembly 111

12 - Circlip
14 - 6th speed selector gear
15 - Synchromesh ring of 6th gear
16 - Mobile sleeve/synchroniser body of the 5th and 6th gear
❑ Release along with the 6th gear mobile pinion ⇒ Item 17 (page 112) after removing the securing ring
⇒ page 114
❑ Assembling the mobile element/synchroniser body. ⇒ page 116 and ⇒ page 116
17 - Circlip
19 - Synchromesh ring of 5th gear
20 - 5th gear wheel
22 - Circlip
❑ When tapered roller bearing ⇒ Item 21 (page 112) or input shaft ⇒ Item 5 (page 111) are renewed:
determine thickness of required circlip ⇒ page 117
24 - Shim
❑ Determine thickness ⇒ page 119
25 - Gearbox
26 - Spring
27 - Mobile element
28 - Synchromesh hub
29 - Locking element
❑ 3 pieces
4.2 Secondary shaft for 5th/6th and reverse

gear: disassembly and assembly


equipment required
♦ Kit (case) -T20022- , see
see equivalent
⇒ page 140
Pulling out tapered roller bearing outer race
Note
Once the part is extracted, check if the shim is damaged and

change it if necessary.
Extraction of the outer roller bearing rings and the bearing bushes
using the kit -T20140-
Insert the outer ring of the roller bearing into the clutch casing
– Fit the shim underneath the outer ring.
Extract the inner ring of roller bearing

– Remove the securing ring.
– Before fitting the extractor, fit the adapter -U 40200/1- as a
base onto the secondary shaft.
Extract the mobile element/synchroniser body for the 5th and 6th
gear along with the 6th mobile pinion
– Remove the securing ring before releasing
– The flat base -U 40100/3- must rest on the mobile pinion of the
6th gear.
Release the sleeve from above the reverse gear mobile pinion
– Remove the securing ring before releasing

Release the synchroniser body for the reverse gear

– Remove the mobile element from the synchroniser body be‐
fore installing the U 40100/3.
Installation position of the synchroniser body for the reverse gear

• The limit -arrow A- of the reverse gear mobile element should
point to the secondary shaft teeth -arrow B-.
Insert the synchroniser body for the reverse gear

– Fit the mobile element with the synchroniser ring before fitting
the reverse gear mobile pinion.
Insert the sleeve -A-

Installation position: the wide collar must point towards the re‐
verse gear mobile pinion.
Check 5th and 6th gear synchroniser ring for wear.

– Press the synchroniser ring against the mobile pinion cone
and measure the distance -a- with a thickness gauge.
Assembly level Wear limit
1.0 … 1.7 mm 0,5 mm
Disassembly and assembly of the mobile element/synchroniser

body for the 5th and 6th gear
– To disassemble, the springs must be removed -1-.
2 - Locking element
3 - Mobile element
4 - Synchromesh hub
– To assemble, fit the mobile element onto the synchroniser
body.
• Installation position: The smaller slots -arrow A- in the syn‐
chronising hub should be in line with the slots -arrow B- in the
locking collar.
Assemble the mobile element/synchroniser body of the 5th and

6th gear
• Move the mobile element on the synchromesh body.
– Fit locking pieces and install springs offset by 120º.
• The protruding end of the spring should enter into the locking
element allotment.

Pressing on 5th and 6th gear locking collar/synchronising hub


– Determine the thickness of the securing ring ⇒ page 117 and
fit it.

– Determine the thickest circlip that will just fit and install it. For
Part Nos. refer to ⇒ Parts catalogue .
Thickness of the securing ring (mm)
1,79 1,83 1,86
1,89 1,92 1,95
1,98
ing

5 Secondary shaft for 5th/6th and re‐

verse gear: adjustment
The secondary shaft should always be readjusted when any of
the following components have been changed:
♦ Gearbox
♦ clutch housing
♦ Secondary shaft for 5th/6th and reverse gear
♦ Conical roller bearings
Adjustment chart
• The gearbox is secured on the assembly stand.
• The sealing surfaces of both the gearbox and the clutch should
be free of sealant.
• To carry out the measurement, only fit the shaft to be meas‐
ured.

equipment required
⇒ page 138
5. Secondary shaft for 5th/6th and reverse gear: adjustment 119

– Insert the roller bearing outer ring with a 1.70 mm shim into
the gearbox housing; to do this support the housing under‐
neath the bearing allotment.
– Insert the secondary shaft for the 5th, 6th and reverse gears
into the clutch housing.
– Fit the gearbox housing over and tighten the bolts -A- and
-B- diagonally with the correct tightening torque.

– Fit the measurement tools and secure them with a bolt

-arrow- in the clutch housing.
mm.
may be lifted.
– Read the value indicated by the dial gauge and note it (in the
example: 0.25 mm).
Note
When loosening the bolts securing the clutch housing to the gear‐
box, no value is indicated on the dial gauge, the shim of 1.95 mm
or that of 2.20 mm must be fitted to make the measurement.
Determining thickness of shims

The specified bearing preload is attained by subtracting the meas‐
ured value (0.25 mm) from the inserted shim (1.70 mm) and
adding a constant value for preload (0.20 mm).
Example:
Shims fitted 1.70 mm
- measured value 0,25 mm
+ Pressure (const. value) 0.20 mm
Thickness of shim 1,65 mm
– Determine shim thickness using the table; part number ⇒
Current parts catalogue .
Thickness of shims 6) in mm
1,50 1,70 1,90 2,10
1,55 1,75 1,95 2,15
1,60 1,80 2,00 2,20
1,65 1,85 2,05 2,25
– Take off gearbox housing and pull tapered roller bearing out
of gearbox housing.
– Extract the conical roller bearing outer ring and the bearing
– Remove the shim fitted (1.70 mm) from the gearbox housing.
5. Secondary shaft for 5th/6th and reverse gear: adjustment 121

– Insert the roller bearing outer ring with the shim of the deter‐
mined thickness (in this case 1.65 mm) into the gearbox
housing; to do this support the housing directly underneath the
bearing allotment using the kit (case) -U 40200A- .
Measurement
• The required shim should already be fitted

mm.
may be lifted.
• The gauge should now be properly selected with levelling dosc
worth a value of 0.15 ... show 0.25 mm.

39 – Final drive - differential

1 Seals for flanged shafts: replacement
1.1 Seal for flanged shaft, left hand side:

changing

equipment required
⇒ page 138
♦ Wrench -T20203- , see
alent ⇒ page 139
1. Seals for flanged shafts: replacement 123

1.1.1 Procedure:
• Gearbox must be installed.
– Remove front left-hand wheel.
– Remove central noise insulation -Fasteners 1 ... 3-.
– Unbolt the drive shaft from the gearbox flange.
– Remove left noise insulation ⇒ Bodywork, exterior fitting work;
Rep. Gr. 66 ; Exterior equipment .
WARNING
To loosen the collar bolts on the wheel drive shaft, the wheel
bearing must not have any pressure on it (the vehicle must be
lifted off its wheels)
– Remove the left hand side drive shaft ⇒ Running gear, axles,
steering; Rep. Gr. 40 ; Front wheel suspension .
– Have a second mechanic apply the footbrake.

– Unscrew the bolt securing the left flanged shaft using the
spanner -T20203- ; to do this, screw two bolts into the flange
and immobilise the shaft with a lever.
– Pull out the flanged shaft.
– Extract the flanged shaft seal using the extractor -T20143/1- .
124 Rep. Gr.39 - Final drive - differential

– Lightly lubricate outer edge of new seal.

– Fit the new seal until it reaches the limit without leaning it on
the tube element -T10088- .
– Press the flanged shaft against the gearbox housing and
screw it in.
– Fit the left hand side drive shaft ⇒ Running gear, axles, steer‐
ing; Rep. Gr. 40 ; Front wheel suspension .
– Add gear oil to the manual gearbox and check the oil level .
Torque settings
Component Nm
Flanged shaft to differential 25
1.2 Right flanged shaft seal: replacing



equipment required
⇒ page 138
♦ Wrench -T20203- , see
alent ⇒ page 139
1.2.1 Procedure:
• Gearbox must be installed.
– Unbolt the front right-hand wheel.
– Remove central noise insulation -Fasteners 1 ... 3-.
– Unbolt the drive shaft from the gearbox flange.
– Remove right hand side noise insulation ⇒ Bodywork, exterior
installation work; Rep. Gr. 66 ; Exterior equipment .
WARNING
To loosen the collar bolts on the wheel drive shaft, the wheel
bearing must not have any pressure on it (the vehicle must be
lifted off its wheels)
– Remove the right hand side drive shaft ⇒ Running gear, axles,
steering; Rep. Gr. 40 ; Front wheel suspension .

– Have a second mechanic apply the footbrake.

– Remove the thermal protection cover for the right hand side
drive shaft from the engine.

– Unscrew the bolt securing the left flanged shaft using the
spanner -T20203- ; to do this, screw two bolts into the flange
and immobilise the shaft with a lever.
– Pull out the flanged shaft.
– Extract the flanged shaft seal using the extractor -T20143/2- .
– Lightly lubricate outer edge of new seal.


– Fit the new seal until it reaches the limit without leaning it on
the tube element -T10088- .
– Press the flanged shaft against the gearbox housing and
screw it in.
– Fit the left hand side drive shaft ⇒ Running gear, axles, steer‐
ing; Rep. Gr. 40 ; Front wheel suspension .
– Add gear oil to the manual gearbox and check the oil level .
Torque settings
Component Nm
Flanged shaft to differential 25

2 Adjustment chart
Note
Whenever carrying out work on the gearbox, it is only necessary

to readjust the secondary shaft for 1st to 4th gear, the secondary
shaft for 5th/6th and reverse or the differential when pieces that
affect the adjustment directly are replaced. Consult the following
table to avoid unnecessary adjustment work.
Component replaced: Adjustment must be made to the

Secondary shaft Secondary shaft Differential:
for 1ª to 4ª gear for 5th/6th and
reverse gear
Gearbox x x x
clutch housing x x x
Input shaft:
Secondary shaft for 1ª to 4ª gear x
Secondary shaft for 5th/6th and reverse gear x
Differential casing x
Input shaft roller bearings
Roller bearing socket for secondary shaft for 1st to 4th x
gear
Conical roller bearing socket for secondary shaft for x
5th/6th and reverse gear
Differential roller bearing x
2. Adjustment chart 129

3 Differential: assembly and disassem‐

bly
3.1 Differential: installation overview
Note

♦ Adjust the differential whenever the roller bearings, differential
casing, gearbox casing or clutch housing are replaced
⇒ page 134 .
♦ Heat the inner ring of the roller bearing to 100 ºC before fitting.
1 - Gearbox
2 - Shim
❑ Determine thickness
⇒ page 134
5 - Differential casing
❑ With riveted crown
8 - Glass
❑ 0.65 mm thick
interior diameter rebate
should point towards the
seal
9 - clutch housing
10 - Insert shaft oil seal
❑ Replace with gearbox
installed, Passat and Eos ⇒ page 125
11 - O ring
❑ replace

12 - Insert shaft dust guard

❑ Screw in with threaded element ⇒ Item 23 (page 131)
14 - Insert shaft
15 - Compression spring for the flanged or insert shaft
❑ Fitted behind the flanged or insert shaft
16 - Attack washer
❑ Installation position: with collar towards the spring, the protrusions towards conical ring
17 - Conical ring
❑ With rebate for the thrust washer
❑ Installation position: with conical side towards the differential casing
18 - Circlip
❑ The conical ring, the thrust washer and the compression spring all remain in place when the flanged or
insert shaft is removed
19 - Planet gear
❑ Installation
20 - Planet gear shaft
❑ Release using a mandrill
21 - Elastic pin
❑ To hold the planet gear shaft
22 - Satellite
23 - Threaded component
24 - Set of thrust washers
❑ Fit with gear oil.
26 - Flanged shaft oil seal
❑ Replace with gearbox installed, Passat and Eos ⇒ page 125
3.2 Differential: assembly and disassembly

3. Differential: assembly and disassembly 131


equipment required
see equivalent
⇒ page 140
♦ Kit (case) -U 40300- , see equivalent ⇒ page 140

Remove the outer ring of the roller bearing from the clutch casing
– Extract the conical roller bearing outer ring and the bearing
Note
Once the part is extracted, check if the shim is damaged and

change it if necessary.
– Fit the shim first.
• Shim installation position: the interior diameter rebate should
point towards the seal

• Before inserting the roller bearing inner ring it must be heated
using the hot air blower -SAT 1416- until a temperature of 100
°C.
Note
♦ Ensure that the flat base -U 40100/3- hooks are well secured
to the inner rings of the roller bearings.
♦ Ensure that the roller bearing cage is not trapped when the
internal rings of the differential casing are removed.
– Before fitting the extractor, fit the kit (case) -U 40300- with the
adaptor -U 40300/13- .

ing
– Use the extractor kit -T20140- with adaptor -T20140/30- .
– The gear housing Adapter -U 40450/1- with the Adapter -U
40450/11- , Adapter -U 40450/4- , Adapter -U 40450/5- and
the Adapter -U 40450/10- and use as a support for connecting
the inner ring of the pressure tool -U 10103- .
Removing and fitting the elastic pin for the planet gear shaft
Removing:
– Cover the inner ring of the roller bearing to avoid damaging it
or contaminating it with shavings.
– Expel the elastic pin by using a chisel on the edge groove.
Installing:
– Insert the elastic pin to the limit on the planetary gear casing.
Fitting sun gear and planetary gears

– Fit the complete assembly of thrust washers with gear oil.
– Fit the two sun gears and secure them (for example using the
input axle).
– Fit the planetary gears offset by 180° and rotate them inwards.
– Insert the planet gear shaft -arrow A- to the first planet gear.
– Fit the threaded components -arrow B- to the sun gears.
• Installation position: Stepped shoulder towards sun wheel
– Insert the planet gear shaft to the final position and secure it
with the elastic pin.
3.3 Differential: Adjust

The differential should always be readjusted when any of the fol‐
lowing components have been changed:
♦ Gearbox
♦ clutch housing

♦ Differential casing
♦ Differential roller bearings
Adjustment chart ⇒ page 129 .

equipment required
♦ Kit (case) -U 40300- , see
• Press tapered roller bearing with shim (0.65 mm thick) into
clutch housing.
– Press the gearbox casing directly onto the base of the bearing
using the kit (case) -U 40200A- .
Note
The tapered roller bearing inner and outer races are paired. Do
not mix them up.

– Support the gearbox casing on the adapter -U 40450/1- with
the adapter -U 40450/11- , the adapter -U 40450/4- , the
adapter -U 40450/5- and the adapter -U 40450/10- and as a
base for connecting the inner ring, the installation tool -U
10103- .
– Insert the differential on the clutch casing.
– Fit on the gearbox casing and tighten the 5 bolts with the cor‐
rect torque.
– Press the differential towards the clutch casing rotating it 8
times.
– Press the differential towards the gearbox casing rotating it 8
times.
– Fit the support -T20020- and the measurement tool together
onto the gearbox casing.
– Fit the gauge and set to “0” with a pretension of 1 mm.

A - 30 mm gauge extension
– Move the differential gear up and down while reading the
measurement on the gauge and noting the results (for exam‐
ple: 0.70 mm).
Determining thickness of shim:
The specified pre-tension for the bearing is obtained by adding a
constant pressure value (0.25) to the measured value.
Example:
Average value 0,70 mm
+ Pressure (const. value) 0,25 mm
Shim thickness = 0,95 mm
– Determine washer or shim thickness using the table; part
number ⇒ Current parts catalogue .
Thickness of shims 7) 8) in mm
0,65 0,85 1,05 1,25
0,70 0,90 1,10
0,75 0,95 1,15
0,80 1,00 1,20
7) If the thickness of the shim required is larger than indicated on the table, two
shims may be fitted to achieve the required thickness. In this case, fit the thicker
shim first.
– Remove the gearbox casing.

ing
– Use the extractor kit -T20140- with adaptor -T20140/30- .
– Fit the washer or shims of the required thickness (thickest
first).
– Press outer race in again and tighten gearbox housing to
specified torque.
– Support the gearbox casing on the adapter -U 40450/1- with
the adapter -U 40450/11- , the adapter -U 40450/4- , the
adapter -U 40450/5- and the adapter -U 40450/10- and as a
base for connecting the inner ring, the installation tool -U
10103- .

4 Equivalence table according to ap‐

plicability
SEAT tool VW / AUDI tool
Pliers -A 81124- Pliers -VW 161A- ⇒ page 153
Hydraulic column jack -SAT Hydraulic jack -V.A.G 1383 A-
1040- See image of the tool or equip‐
ment ⇒ page 143
Brake bleeder -SAT 1175B- Brake filling and bleeding equip‐
ment -VAS 5234- See image of
the tool or equipment
⇒ page 157
Hydraulic circuit clamp (fe‐ No equivalent
male) -SAT 1210-
Hydraulic circuit clamp (male) No equivalent
-SAT 1211-
Electric blower -SAT 1416- Electric blower -VAG 1416- See
image of the tool or equipment
⇒ page 144
Torque wrench set -SAT Torque wrench socket -V.A.G
8010- 1331- or torque wrench socket -
V.A.G 1332- See image of the
tool or equipment ⇒ page 140
retention tool -T10027- Locking bolt -T10027 A- See im‐
age of the tool or equipment
⇒ page 142
Tappet -T10088- Push rod -3305- See image of
⇒ page 155
Tappet -T10203- No equivalent
Support -T20020- Universal measurement clock
holder -VW 387- See image of
⇒ page 154
Kit (case) -T20022- Roller bearing bush extractor -
V.A.G 1582- See image of tool or
equipment ⇒ page 154
Pliers -T20029- Push rod -VAS 5024A- See im‐
⇒ page 145
Pliers -T20059B- Pliers -T10005- See image of the
Pliers -T20072A- Pliers -V.A.G 1275- See image
of the tool or equipment
⇒ page 142
Tappet -T20099- All-purpose tool -VW 771- See
⇒ page 152
Pressure tool -T20100- Tube element -VW 519- See im‐
⇒ page 153
Wrench -T20118- No equivalent
Pressure tool -T20129- No equivalent
Tappet -T20130- Push rod -T40008- See image of
⇒ page 141


Gearbox support -T20138C- Gearbox support assembly
-3282- See image of the tool or
Tappet -T20139- Guide element -VW 436A- , Inlay
mandril -3264- See image of the
Extractor kit -T20140- No equivalent
Pressure tool -T20141- Pressure plate -VW 401- , Tube
element -2040- See image of the
Pressure tool -T20141- Push rod -40-21- See image of
⇒ page 152
Pressure tool -T20141- Synchronizing key -VW 473- , re‐
tracting press -VW 412- See im‐
age of tool or unit ⇒ page 155
Extractor kit -T20143- Extraction hook -VW 771/37-
See image of tool or equipment
⇒ page 147
Extractor kit -T20143- No equivalent
Base -T20145- No equivalent
Tappet -T20153- Tube element -VW 423- See im‐
⇒ page 151
Base -T20172/1- Support plate -VW 309- , Sup‐
port equipment -VW 313- See
⇒ page 146
tower -T20172/2- Support plate -VW 309- , Sup‐
port equipment -VW 313- See
⇒ page 146
Gear box support. - Gearbox support assembly -VW
T20172/4A- 353- See image of the tool or
Drip tray -T20173- Drip tray -VAS 6208- See image
⇒ page 144
retention tool -T20176- Retention tool -3067- see image
for tool or unit ⇒ page 141
Support equipment -T20186- Gearbox suspension tool -3336-
See image of the tool or equip‐
ment ⇒ page 149
Pressure tool -T20187- No equivalent
Tappet -T20188- Mandrel -T10169- See image of
⇒ page 145
Tappet -T20188- Guide piece -VW 439- See im‐
⇒ page 150
Wrench -T20203- Socket -T10072- See image of
⇒ page 155
Centre guide -U 10050-10- Centring mandrel -T10097- See
⇒ page 142
4. Equivalence table according to applicability 139


Pressure tool -U 10103- Tightening plate -3005- . See im‐
⇒ page 157
Support -U 30025E- Support -10-222 A- See image of
⇒ page 146
Pressure tool -U 30042- Hose clamps -3094- See image
⇒ page 156
retention tool -U 40007- Support bridge -30-211A- See
⇒ page 148
Extractor kit -U 40100B- No equivalent
Kit (case) -U 40200A- No equivalent
Tappet -U 40204- Mandrel -T10168- See image of
⇒ page 150
Kit (case) -U 40300- No equivalent
Tappet -U 40404- No equivalent
Kit (case) -U 40450A- No equivalent
4.1 Graphic information on SEAT equivalent

tools and equipment
4.1.1 Torque wrench -V.A.G 1331- or Torque
wrench -V.A.G 1332- .
Torque wrench -V.A.G 1332-

4.1.2 Pressure tool -T40008-
Application
4.1.3 retention tool -3067-
Application

4.1.4 Centring mandrel. -T10097-
Application
4.1.5 Pliers -V.A.G 1275-
4.1.6 Locking bolt -T10027 A-

Application
4.1.7 Engine assembly mounting -V.A.G 1383

A-
4.1.8 Gearbox support assembly -3282-
Application

4.1.9 Drip tray -VAS 6208-
4.1.10 Pliers -T10005-
Application
4.1.11 Electric blower -VAG 1416-

Application
4.1.12 Clamp pliers -VAS 5024A-
4.1.13 Mandril -T10169-
Application

4.1.14 Support -10-222 A-
Application
4.1.15 Support plate -VW 309- , Support equip‐

ment -VW 313-
Application

4.1.16 Gearbox support assembly -VW 353-
Application
4.1.17 Extraction hook -VW 771/37-
Application

4.1.18 Support bridge -30-211A-
Application
4.1.19 Guide element -VW 436A- , Inlay man‐

dril -3264-
Guide element -VW 436A-
Inlay mandril -3264-

Application guide element -VW 436A-
Application inlay mandril -3264-
4.1.20 Gearbox suspension tool -3336-
Application

4.1.21 Mandril -T10168-
Application
4.1.22 Guide element -VW 439-
Application

4.1.23 Tube element -VW 423-
Application
4.1.24 Pressure plate -VW 401- , Tube element

-2040-
Pressure plate -VW 401-
Tube element -2040-

Application
4.1.25 Universal tool -VW 771-
Application
4.1.26 Inlay socket -40-21-

Application
4.1.27 Pliers -VW 161A-

Application
4.1.28 Tube element -VW 519-
Application

4.1.29 Universal bracket for gauge -VW 387-
Application
4.1.30 Roller bearing bush extractor -V.A.G

1582-
Application

4.1.31 Pressure tool -3305-
Application
4.1.32 Socket spanner -T10072-
4.1.33 Pressure tool -VW 473- , Inlay press -

VW 412-
Pressure tool -VW 473-

Press die. -VW 412-
Application
4.1.34 Hose clamps -3094-
Application

4.1.35 Brake filling and bleeding equipment -

VAS 5234-
4.1.36 Tightening plate -3005-
Application

6-Speed Manual Gearbox

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

6-Speed Manual Gearbox

Uploaded by

Copyright:

Available Formats

Service

0A8 6-speed manual gearbox

Service Department. Technical Information

5.1 Gearbox housing - installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

0A8 Manual gearbox

Identification letters and manufacture date of gearbox -arrow-

1.1 Codes, engine allocation, gear ratios

6-speed manual gear‐ 0A8 6 speed

1.2 Filling amounts

2 Rep. Gr.00 - Technical data

2 Overview of the drive force

The -arrows- indicate direction of movement.

2.1 Calculation of the gear ratio “i”

2. Overview of the drive force 3

i = Z2 : Z1 Z1 = Number of teeth of driver pinion,

4 Rep. Gr.00 - Technical data

3 General repair instructions

♦ Only use genuine Seat parts!

3. General repair instructions 5

O-rings, seals, gaskets

6 Rep. Gr.00 - Technical data

3. General repair instructions 7

♦ The temperature can be measured with the digital thermom‐

• The legs of the bridge /1 have different sized recesses

8 Rep. Gr.00 - Technical data

1.1 Pedal mechanism, clutch pump - Assembly overview

1. Clutch mechanism: repairs 9

16 - Over-centre spring seat

1.2 Remove and install bearing bracket and

Special tools and workshop

10 Rep. Gr.30 - Clutch

1. Clutch mechanism: repairs 11

– Remove the hexagonal nuts -arrows- and extract the pedal

12 Rep. Gr.30 - Clutch

Lubricate the end of the tappet with lubricating grease, according

– Fit the clutch master cylinder to the front panel.

If necessary, to aid the fitting of the connection on the clutch ped‐

– Tighten hexagonal nut with collar: always replace: Starting

1. Clutch mechanism: repairs 13

Replace the O-rings.

1.3 Removing and installing clutch pedal

1.3.2 Assembly and adjustment

14 Rep. Gr.30 - Clutch

1.4 Over-centre spring: removing and fitting

1. Clutch mechanism: repairs 15

1.5 Clutch pedal: removing and fitting

♦ Pliers -T20059B- , see equivalent ⇒ page 138

♦ If the vehicle is fitted with a coded radio (anti-theft code), check

16 Rep. Gr.30 - Clutch

– Unscrew the nut -A-, always replace this.

1. Clutch mechanism: repairs 17

1.6 Clutch hydraulic system: assembly overview

1 - Brake fluid reservoir

18 Rep. Gr.30 - Clutch

Remove allotment -A- by levering in the direction of the arrow

Install the clutch master cylinder operating rod in the allotment

– For installation a new O-ring -3- must be fitted to the slave

1. Clutch mechanism: repairs 19

20 Rep. Gr.30 - Clutch

2 Clutch release assembly, clutch

2.1 Clutch release assembly, slave cylinder - Installation overview

2.2 Clutch slave cylinder: removing and in‐