SEAT Workshop Service and Repair Manuals

Installation Installation position of 5th gear wheel

–  The lobe present -arrow- on the internal diameter of the gear must be orientated towards the gearbox casing. –  Heat the gear of the 6thª gear to approx. 100 °C with the electric blower -SAT 1416-.

–  Press in sprocket with adapter -U 40200/20-.

Check 5thª gear synchromesh ring for wear. –  Before checking for wear, thoroughly clean the synchroniser ring and 5th gear mesh. –  Fit 5th gear synchromesh ring on ratchet. Press the synchro ring on the sprocket and measure the elevation “a” with a thickness jig.

Synchroniser ring	Measurement “a” on new synchroniser	Wear limit
5. Road speed	1,1 ... 0.07 in	0.02 in

–  Fit 5th gear ratchet with the needle bearing. –  Fit 5th gear synchromesh ring on ratchet.

Install synchromesh assembly of 5th gear   Note Before fitting the assembly, check the synchromesh for wear Install the 5th gear synchromesh unit as follows: –  Place the mobile sleeve -2- on the synchromesh bush -3-, so that the grooves to house the locking pins -arrows A- on both components coincide -4-. –  Install locking pieces -4-. Installatoin position: Recess -arrow B- pointing toward sharp teeth on selector sleeve -2-.

Install springs in synchromesh assembly of 5th gear –  Install spring rings 120° offset below extensions -C-. The bent end of the spring rings must be located in front of the locking elements -arrows-. –  Check that the teeth terminating in end -A- of the sliding sleeve are located in the same direction with the most pronounced lug -B- of the axle box. –  Check that locking pins are correctly installed → Anchor.

Assembly position of the 5th gear synchromesh/mobile element assembly –  Instal 5th gear wheel on input shaft so that the teeth on the conical selector sleeve -arrow 1- and the high collar on the synchromesh element -arrow 2- point toward the transmission housing. –  Align recesses -arrow 3- on synchromesh hub to locking elements on synchromesh ring (-arrows- lower figure).

5thª gear synchromesh ring with locking elements incorporated -arrows- –  Cover all holes with rag to prevent foreign body from penetrating into the transmission.

–  Fit synchromesh assembly on 5th gear ratchet. Use the adaptor -U 40200/20-.   Note When fitting synchromesh assembly to 5th gear, check the 5th gear synchromesh ring turns freely. –  Clean bolt holes for mounting synchromesh element and 5th gear with tap to remove residues of bolt securing agent. Otherwise bolts can break. –  Partially screw mounting bolts → Item onto synchromesh element and 5th gear wheel.

Installation position of the plate spring –  The concave side of the plate springs -arrows- should point toward the synchronous hub and 5th gear wheel.

Before tightening mounting bolts on synchromesh hub and 5th gear wheel, press 5th gear selector sleeve downward -arrow 1- and engage gear. Also shift into 1st gear with shift lever -arrow 2- and -arrow 3-. The input and output shafts remain locked when two gears are engaged; the synchromesh hub and 5th gear wheeldo not turn. Tighten the bolts -A- to a torque of 80 Nm. –  Install 5th gear connection prong with a torque of 25Nm.

Adjust the mobile sleeve and the prong for the 5th gear –  Shift into 5th gear. Loosen the bolt -B-. Press the mobile sleeve and the gear mouth in the direction of the -arrow-; then tighten the bolt -1- to 25 Nm. l  Control measurement: Between the mobile sleeve and the mobile pinion, a thickness gauge of 0.2 mm cannot be inserted. If necessary, repeat the adjustment process. –  Shift out of 5th gear. The sleeve must be situated in neutral position and the synchromesh ring must turn freely in this position. –  Successively select all gears several times. –  Install the gasket and gearbox casing cover. –  Tighten the bolts to secure the gearbox casing cover to a torque of 10 Nm. –  Place the drain bolt and tighten to 25 Nm.

–  Screw in the drain plug -arrow- with a wrench -U 40090-. –  Fill the gearbox with oil → Booklet1, noting the quantity filled → Chapter –  Install left front wheel well shell → Body - outer assembly work; Rep. Gr.66 –  Install center noise insulation → Body - outer assembly work; Rep. Gr.50. –  Fit the front left hand side wheel.