SEAT Workshop Service and Repair Manuals

Dismantling and assembling output shaft for 3rd and 4th gear

Special tools and workshop equipment required

t	Pressure plate -VW 401-

t	Pressure plate -VW 402-

t	Press die. -VW 407-

t	Press die. -VW 412-

t	Tube -VW 415 A-

t	Thrust piece -VW 431-

t	Thrust piece -VW 433-

t	Thrust piece -VW 454-

t	Support rails -VW 457-

t	Thrust pad -VW 510-

t	Tube -VW 519-

t	Support plate -VW 801-

t	Tightening plate -30 - 11-

t	Tightening plate -40 - 105-

t	Thrust piece -3118-

t	Roller bearing bush extractor -V.A.G 1582-

t	Adapter -V.A.G 1582/4-

t	Adapter -V.A.G 1582/7-

t  -1-Internal puller 46...58 mm, e.g. -Kukko 21/7- t  -1-Internal puller 56...70 mm, e.g. -Kukko 21/8- t  -4-Counter support , e.g. -Kukko 22/2- t  Feeler gauge

Pulling off tapered roller bearing inner race for bearing in gearbox housing –  Before fitting puller, position press tool -VW 431- in output shaft and set thrust plate -40-105- on it. –  Remove retaining ring.

Pressing off gear wheel for 6th gear

Pressing off gear wheel for 5th gear with synchromeshed gear for 3rd gear –  Place tools beneath 3rd gear synchromeshed gear so that no parts will be damaged during pressing.   Note If 5th gear wheel is close to circumferential groove for retaining ring -arrow- during pressing procedure, secure output shaft from falling. –  Remove retaining ring.

Pressing off 3rd and 4th gear synchro-hub and locking collar with 4th gear synchromeshed gear

Checking 3rd and 4th gear inner ring for wear –  Press inner ring onto cone of synchromeshed gear and measure gap -a- using a feeler gauge.

Dimension -a-	Installation dimension	Wear limit
3rd and 4th gears	0.75 … 1.25 mm	0.3 mm

Checking 3rd and 4th gear synchro-rings for wear –  Press synchro-ring, outer ring and inner ring onto cone of synchromeshed gear and measure gap -a- using a feeler gauge.

Dimension -a-	Installation dimension	Wear limit
3rd gear	1.0 … 1.8 mm	0.5 mm
4th gear	1.0 … 1.9 mm	0.5 mm

–  Install synchromeshed gear for 4th gear with needle bearing.

Installation position of 4th gear outer ring, inner ring and synchro-ring –  Place inner ring -A- on 4th gear synchromeshed gear. l  The tabs -arrows 1- - must face the outer ring -B-. –  Fit outer ring -B-. l  Lugs -arrows 2- engage in notches -arrows 3- of synchromeshed gear. –  Fit synchro-ring -C-. l  The grooves -arrows 4- insert onto the tabs -arrows 1- of the inner ring-A-.

Dismantling and assembling 3rd and 4th gear locking collar and synchro-hub –  To dismantle, remove springs -1-. 1 -  Spring 2 -  Locking piece 3 -  Locking collar 4 -  Synchro-hub »installation position« → Fig. –  To assemble, slide locking collar over synchro-hub. l  Installation position: narrower notches in synchro-hub align with notches in locking collar.

Assembling locking collar and synchro-hub for 3rd and 4th gears l  Locking collar has been pushed over synchro-hub. –  Insert locking pieces and install springs offset 120°. l  Angled end of spring must locate in hollow locking piece.

Installation position of locking collar with synchro-hub for 3rd and 4th gears Higher shoulder of synchro-hub -arrow- faces 4th gear. l  Synchromeshed gear for 4th gear is placed on shaft together with needle bearing and synchro-rings.

Pressing on 3rd and 4th gear locking collar and synchro-hub –  Install retaining ring.

Installation position of 3rd gear outer ring The tabs -arrows- must point towards the unit of the mobile element and synchroniser body -A-.

Installation position of synchro-ring -A- (3rd gear inner ring) Lugs -arrows 1- locate in notches -arrows 2- of synchro-ring -B-.

Installation position of 3rd gear synchromeshed gear Higher shoulder -A- faces 4th gear -B-. Notches in shoulder -arrows- engage in lugs of outer ring → Fig.. –  Install 3rd gear synchromeshed gear with needle bearing. –  Heat gear wheel for 5th gear to approx. 150° C.

Pressing on gear wheel for 5th gear –  Press on gear wheel quickly so that heat is not immediately transferred to output shaft. –  Heat gear wheel for 6th gear to approx. 150° C.

Pressing on gear wheel for 6th gear –  Fit the securing ring.   Note When 5th gear wheel has been pressed off in previous step, let output shaft cool off. –  Press on gear wheel quickly so that heat is not immediately transferred to output shaft. –  Insert locking device for gear wheel for 6th gear.

Pressing on tapered roller bearing inner race for bearing in gearbox housing   Note Pull off tapered roller bearing inner race for bearing in gearbox housing → Fig..

Pulling outer race for tapered roller bearing out of gearbox housing A -  Spindle from counter support, e.g. -Kukko 22/2- B -  Internal puller, 46…58 mm, e.g. -Kukko 21/7- –  Place new shim with previous value under outer race.

Pressing tapered roller bearing outer race into gearbox housing

Pulling off tapered roller bearing inner race for bearing in clutch housing

Pressing on tapered roller bearing inner race for bearing in clutch housing –  Before setting up pulling device, set thrust plate -30-11- on output shaft.

Pulling tapered roller bearing outer race out of clutch housing A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 56…70 mm, e.g. -Kukko 21/8- –  Place new shim with previous value under outer race.

Pressing tapered roller bearing outer race into clutch housing –  Support clutch housing with tube -VW 415 A- directly below bearing support.