SEAT Workshop Service and Repair Manuals

Secondary shaft: disassembly and assembly Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Extractor kit -T20140-, see equivalent → Anchor

t	Measurement tool -T20171-, see equivalent → Anchor

t	Extractor kit -U 40100B-, see equivalent → Anchor

t	Kit (case) -U-40200A-, see equivalent → Anchor

t	Kit (case) -U-40300-, see equivalent → Anchor

Extract the secondary shaft cylindrical roller bearing from the clutch housing –  When doing this, squeeze the securing ring with pliers.

Insert the cylindrical roller bearing into the clutch housing –  While doing this, squeeze the securing ring with pliers. –  Remove the pliers before the bearing is in its final installation position. The securing ring should insert into the slot of the clutch housing.

Release the securing ring -1- from its allotment   WARNING Avoid the uncontrolled release of the securing ring.

Disassemble the mobile element/synchroniser body for 1st and 2nd gear –  After removal of the securing ring, release the 2nd gear mobile pinion and the mobile element with the synchroniser body together.

Installation position of the 3rd and 4th gear mesh –  Fit the 4thª gear pinion -A- on the secondary shaft. Installation position: The collar -arrow 1- must be orientated towards the 3rd gear mesh -B-. –  Fit the securing rings -2- and -3-. –  Fit the 3rdª gear pinion -B- on the secondary shaft. Installation position: The collar -arrow 2- must be orientated towards the 4th gear mesh -A-. –  Fit the securing ring -1-.

Wear of the 1st and 2nd gear interior synchroniser ring: testing   Note Before measuring the wear of the synchroniser rings, thoroughly clean the rings and their corresponding gears. –  Fit a suitable gauge of the measurement tool -T20171- between the mobile pinion and the inner synchroniser ring. Press the inner ring against the gear cone; the measurement tool -T20171- should move freely.

Synchroniser ring	Assembly level	Wear limit
1. and 6th gear	0,75 ... 1.25 mm	0.3 mm

Wear of the 1st and 2nd gear outer synchroniser ring: testing –  Fit the inner synchroniser assembly on the mobile pinion, the measurement tool -T20171- and the outer synchroniser ring. Press the outer ring against the inner synchroniser cone; the measurement tool -T20171- should move freely.

Synchroniser ring	Assembly level	Wear limit
1. and 6th gear	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 projections -arrows 1- should face the outer ring -B-. –  Fit over the outer ring -B-. The tabs -arrows 2- insert into the grooves -arrows 3- of the mobile pinion. –  Fit over the synchroniser ring -C-. The grooves -arrows 4- insert onto the projections -arrows 1- of the inner ring -A-.

Disassembly and assembly of the mobile element/synchroniser body for the 1st and 2nd gear 1 -  Spring 2 -  Mobile element 3 -  Synchromesh hub 4 -  Locking element –  Move the mobile element on the synchromesh body. Installation position: The groove on the front section -arrow A- and the highest collar -arrow B- of the synchroniser body should point towards the outer teeth of the mobile element -arrow C- following assembly. The deepest grooves -arrow D- for the locking elements located on the synchroniser body should coincide with the grooves -arrow E- on the mobile element.

Assembling the mobile element/synchroniser body for 1st and 2nd gear l  Check that the mobile element on the sychronizer body moves without difficulty –  Fit the locking elements in the deepest grooves -arrows- and fit the securing springs off-set by 120º. The folded end of the spring should be located on the inside hollow of the locking element.

Assembling the mobile element/synchroniser body for 1st and 2nd gear on the secondary shaft Installation position: The groove for the prong located on the mobile element should face 1stª gear, the reverse gear teeth towards 2ndª gear. –  Fit the synchroniser ring so that the notches coincide with the locking elements.

Fit the securing ring. –  Fit the 1st and 2nd gear mobile element securing ring on the secondary shaft.

Installation position of 1stª gear exterior ring –  The tabs -arrows- point towards the teeth of the reverse gear.

Installation position of 1stª gear inner ring -A- –  The tabs -arrows 1- insert into the recesses -arrows 2- of the synchroniser ring-B-.

Installation position of 1st gear mobile pinion -A- The highest collar -A- should face 2ndª gear -B-. The recesses in the shoulder -arrows- engage on the lugs on the outer ring → Fig..