SEAT Workshop Service and Repair Manuals

Layshaft: adjusting

Special tools and workshop equipment required

t	Torque spanner -SAT 8010-

t	Universal dial gauge bracket -T20020-

t	Set for exterior point clamps, housing tracks without exit -T20140-

t	Gear box repair set -U-40200A-

Adjust the layshaft when one of the following elements has been replaced: l  Clutch housing l  Layshaft (crown/pinion assembly) l  Layshaft roller bearings Refer to Adjustment chart → Chapter.

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

–  Fit tool -T20020- on the gearbox 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.   Note! While measuring do not move the layshaft. The bearings may settle and make the measurement incorrect. –  Move the layshaft up and down, read the play with the dial gauge taking note of the measurement (e.g.: 0.3 mm). Shim calculation table The bearing tension is obtained by adding a constant pressure value (0.20mm) to the average value (0.3 mm) and the thickness of the shim fitted (0.65mm). Example:

Shim fitted	0.65 mm
+ Average value	0.30 mm
+ Pressure (const. value)	0.20 mm
Required adjusting washer thickness	0.15 mm

The shim needed will be determined by the following table:

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

The existance of different tolerances allows the exact calibration of the thickness of the washer needed. If the thickness of washer needed is greater than the thickness of the washers in the table, two washers can be fitted that make up the required 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, with tool -T20140-. Procedure for extracting the outer ring → Chapter, General instructions for gearbox repairs. –  Remove the 0.65 mm thick washer. –  Fit the shim of the correct thickness (in this case 1.15 mm) into the housing in the outer track of the layshaft roller bearing.

–  Fit the layshaft outer roller bearing track to the clutch housing, with tool -U-40200A/10- and tool -U-40200A/12-. –  Lubricate the roller bearings with gearbox oil. –  Locate the layshaft in its housing in the gearbox casing. –  Fit the bearing housing into the clutch casing, fit the bolts and tighten to 25 Nm +90 °.