SEAT Workshop Service and Repair Manuals

Secondary shaft for 5th / 6th and reverse gear: Disassembling and assembling Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Kit (case) -T20022-, see equivalent → Anchor

t	Extractor kit -T20140-, see equivalent → Anchor

t	Counterhold -T20141-, see equivalent → Anchor

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

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

t	Tappet -U 40404-, see equivalent → Anchor

Extract the outer ring of roller bearing socket   Note After pulling out, check shim for damage and renew 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 –  Before applying the flat base -U 40100/3-, remove the sliding sleeve from the synchromesh ring.

Extract the inner ring of roller bearing

Installation position of the synchroniser body for the reverse gear l  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 reverse gear mobile pinion –  Then fit the securing ring.

Check 5th and 6th gear synchroniser ring for wear. –  Press the synchromesh 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. l  Installation position: the smaller recesses -arrow A- in the synchroniser body must coincide with the recesses -arrow B- of the mobile element.

Assemble the mobile element/synchroniser body of the 5th and 6th gear l  Slide locking collar over synchronising hub. –  Fit locking pieces and install springs offset by 120º. l  The protruding end of the spring should enter into the locking element allotment.

Insert the mobile sleeve / synchroniser body of the 5th and 6th gear –  Then fit the securing ring.

Insert the inner ring of roller bearing –  Determine the thickness of the securing ring → Fig. and fit it.

Determining the correct thickness securing ring –  Determine the thickest securing ring that can be fitted and place it → Spare parts catalogue.

Thickness of the securing ring (mm)
1,79	1,83	1,86
1,89	1,92	1,95
1,98

Insert the inner ring of roller bearing

Remove the outer ring of the roller bearing from the gearbox casing

Fitting the outer ring of the roller bearing into the gearbox casing –  Support the gearbox housing fitting the adapter -U 40200/14- directly underneath the bearing allotment.