SEAT Workshop Service and Repair Manuals

Assembling –  Check wear on inner rings of 1st and 2nd gears → Chapter. –  Check wear on synchromesh rings of 1st and 2nd gears → Chapter.

–  Fit the 4th gear pinion -A- on the secondary shaft. l  The collar -arrow 1- must be orientated towards the 3rd gear mesh -B-. –  Fit the securing rings -2- and -3-. –  Fit the 3rd gear pinion -B- on the secondary shaft. l  The collar -arrow 2- must be orientated towards the 4th gear mesh -A-. –  Fit the securing ring -1-. –  Fit the needle bearing and the 2nd gear mobile pinion on the secondary shaft.

–  Fit the interior ring -A- onto the mobile pinion for 2nd gear l  The slanted reinforcements -arrows 1- should face the outer ring -B-. –  Fit the outer ring -B-. l  The tabs -arrows 2- insert into the recesses -arrows 3- of the mobile pinion. –  Fit the synchroniser ring -C-. l  Notches -arrow 4- engage in lugs -arrow 1- of inner ring -A-. –  Sliding sleeve / syncro-ring assembly for 1st and 2nd gear → Chapter.

–  Install synchromesh and mobile sleeve assembly -3- on secondary shaft. l  The grooves on the mobile sleeve point towards the 2nd gear. –  Rotate the synchronizer ring -1- so that its drive elements are aligned with the free grooves of the synchromesh -2--arrows-.

–  Press the 1st and 2nd gear synchromesh and mobile sleeve assembly on secondary shaft. Fitting position: Groove for selector fork in locking collar points towards 1st gear; reverse gear splines point towards 2nd gear. –  After insertion, check the movement of the synchromesh by rotating the 2nd gear mobile pinion from one side to the other. l  The 2nd gear mobile pinion should rotate easily from one side to the other. –  Turn synchro-ring so that grooves align with locking pieces.

–  Fit retaining ring. –  Fit the 1st gear securing ring on the mobile sleeve / synchromesh assembly.

Installation position of outer ring for 1st gear The lugs -arrows- face the gear teeth of the reverse gear.

Installation position of 1st gear inner ring -A- The lugs -arrow 1- locate in the recesses -arrow 2- in the synchro-ring -B-.

Installation position for 1st gear mobile pinion The highest collar -A- must point towards2nd gear -B-. Notches in shoulder -arrows- engage in lugs of outer ring → Fig..

–  Insert the following components onto the secondary shaft: 5  -  Synchro-ring for 1st gear 4  -  Outer ring for 1st gear 3  -  Inner ring for 1st gear

Installation position of outer ring for 1st gear The lugs -arrows- face the gear teeth of the reverse gear.

Installation position of 1st gear inner ring -A- The lugs -arrow 1- locate in the recesses -arrow 2- in the synchro-ring -B-.

Installation position for 1st gear mobile pinion The highest collar -A- must point towards2nd gear -B-. Notches in shoulder -arrows- engage in lugs of outer ring → Fig.. l  The drive elements should point towards the grooves of the synchromesh ring. 2  -  Needle bearing for 1st gear 1  -  1st speed selector gear l  Rotate the mobile pinion until the outer ring drive elements mesh with the grooves of the mobile pinion (when doing so the mobile pinion visibly moves downwards).