SEAT Workshop Service and Repair Manuals

Layshaft: dismantling and assembling

Special tools and workshop equipment required

t	Gearbox extractor set -U-40100-

t	Gearbox repair set -U-40200-

t	Circlip opening pliers -A-81124-

t	Whenever new gears are fitted consult the technical data → Chapter, Code letters, group numbers, ratios, filling quantities

t	If the layshaft, roller bearings or clutch housing are replaced, the layshaft should be adjusted → Chapter

1 -	Gearbox casing cover

2 -	5th gear safety ring

q

Renew

3 -	Thrust washer

4 -	Sliding 5th gear

q	Fit → Chapter, Assembly sequence

5 -	Gearbox casing

6 -	Needle roller bearing

q	Removing and fitting → Chapter, Gearbox casing and gearbox selector shaft: repairing

7 -	4th gear safety ring

q

Renew

q	Use tool -A-81124- to remove the circlip

8 -

4th gear

9 -	3rd gear safety ring

q

Renew

q	Determine thickness → Chapter, Assembly sequence

q	Use tool -A-81124- to remove the circlip

10 -

3rd gear

q	Installation position → Chapter, Assembly sequence

q	Checking axial clearance → Chapter, Assembly sequence

11 -	Sliding 2nd gear

12 -	Needle bearing for sliding 2nd gear

q	Removing the bush → Chapter, Assembly sequence

q	Fitting the bush → Chapter, Assembly sequence

13 -	Syncromesh ring 2nd gear

q	Checking for wear → Fig.

14 -	Syncromesh assembly for 1st and 2nd gear

q	Assembly → Fig. and → Fig.

q	Remove → Chapter, Assembly sequence

q	Fit → Chapter, Assembly sequence

15 -	Syncromesh ring 1st gear

q	Checking for wear → Fig.

q	Identification → Fig.

16 -	Sliding 1st gear

17 -

Spring

18 -	Sliding sleeve

19 -	Syncromesh hub

20 -	Locking keyways

q

3 units

21 -	Needle roller bearing for 1st gear

22 -	Thrust washer

q	Installation position → Chapter, Assembly sequence

23 -	Clutch housing

24 -

Shim

q	For layshaft

q	Adjustment chart → Chapter

25 -	Outer track, small roller bearing

q	Remove → Fig.

q	Fit → Fig.

26 -	Small roller bearing

q	Remove → Fig.

q	Fit → Fig.

27 -

Layshaft

q	A matched pair with the driveshaft gear; they must be replaced together

q	Adjusting → Chapter

28 -	Large roller bearing

q	Remove → Fig.

q	Fit → Fig.

29 -	Bearing housing

q	With the external roller bearing track and stop for reverse gear

q	The external track should only be replaced together with the large roller bearing and the bearing housing

30 -	Hexagon bolt

q	25 Nm + 90°

Checking syncromesh ring wear –  Press the syncromesh ring onto the cone of the sliding gear and measure dimension -a- with a feeler gauge.

Syncromesh ring	Measurement -a- on a new syncromesh	Wear limit
1st and 2nd gears	1.1 … 1.7 mm	0.5 mm

Identification of syncromesh for 1st gear Identification: 3x1 tooth missing -arrow-. This syncromesh ring can only be fitted to the 1st gear.

Removing the 1st and 2nd gear syncromesh assembly Assembly position of the syncromesh hub: The external indentification groove -arrow- should be aligned with the external teeth of the sliding sleeve. –  Slide the sleeve onto the syncromesh hub. The recesses for the syncromesh locking keys and the sleeve mustline up.

Removing the 1st and 2nd gear syncromesh assembly –  Insert the locking keys and fit the springs at 120° from each other. The angled ends of the springs must locate in the inner hollow of the corresponding locking keys.

Remove the outer track of the small roller bearing

Fit the outer track of the small roller bearing

Removing the small roller bearing

Removing the large roller bearing

Fitting the small roller bearing –  Before fitting the small roller bearing on the layshaft, heat the inside track to 100 °C approx. –  Fit extractor -U-40100/3- to the layshaft under the crown gear on a press. With tool -U-40200/19- side A fit the small bearing to its final position.

Fitting the large roller bearing –  Before fitting the big roller bearing on the layshaft, heat the inside track to 100 °C approx. –  Fit the large bearing on the layshaft and locate with tool -U-40200/19- side B fitting as base extractor -U-40100/4-.