Layshaft: adjustment

Make

SEAT

Model

Leon Mk1

Section

02J 5-speed manual gearbox › Gearbox,mechanics,gears,shafts,internal operation › Layshaft: adjustment

Power transmissionLayshaft: adjustment

Layshaft: adjustment

Special tools and workshop equipment required

t	Gearbox repair set -U-40200-

t	Gearbox repair set -U-40300-

t	Universal dial gauge bracket -T20020-

t	Torque spanner -SAT 8010-

Adjust the layshaft when one of the following elements has been replaced: t  Clutch housing t  Layshaft t  Layshaft roller bearings Refer to Adjustment chart → Chapter

–  Fit the outer track of the layshaft small roller bearings into the clutch housing, with a 0.65 mm thick shim. –  Locate the layshaft in its housing in the gearbox casing. –  Tighten the bearing housing screws to 25 Nm + 90°.

–  Fit tool -T20020- on the clutch casing with a dial gauge. Locate the end of the dial gauge on the layshaft. –  Adjust the dial gauge to “0” with a pre-tension of 1 mm. –  Pull the layshaft alternatively in the direction of the dial gauge. –  Take note of the measurement obtained (e.g. 0.30 mm).   Note! While measuring do not move the layshaft. The roller bearings settle and falsify the measurement. Shim calculation table The bearing tension is obtained by adding a constant pressure value (0.2 mm) to the average value (0.3 mm) and the thickness of the shim fitted (0.65 mm). Example:

Washer fitted	0.65 mm
+ Average value	0.30 mm
+ Pressure (const. value)	0.20 mm
Shim thickness needed	1.15 mm

The shim needed will be determined by the following table: Adjustment table

Thickness (mm)	Spare no.
0.65 0.70	020 311 391 P 020 311 391 Q
0.75 0.80 0.85	020 311 391 020 311 391 A 020 311 391 B
0.90 0.95 1.00	020 311 391 C 020 311 391 D 020 311 391 E
1.05 1.10 1.15	020 311 391 F 020 311 391 G 020 311 391 H
1.20 1.25 1.30	020 311 391 J 020 311 391 K 020 311 391 L
1.35 1.40	020 311 391 M 020 311 391 N

The available variety of stop washers makes it possible to determine exactly the necessary thickness for correct adjustment of the layshaft. –  If the thickness needed is greater than those indicated on the table, two shims can be used that add to the determined value. –  Once the necessary shim has been determined, remove the dial gauge. –  Separate the layshaft. –  Remove the layshaft outer roller bearing track from the clutch housing → Fig.. –  Remove the 0.65 mm thick shim from the clutch housing.

–  Fit the outer track of the small roller bearing in the clutch housing with the correct shim (in this case 1.15 mm). –  Lubricate the roller bearings with gearbox oil. –  Locate the layshaft in its housing in the gearbox casing. –  Tighten the bearing housing screws to 25 Nm + 90°.

01 Transmission

The same page in: Leon Mk2.