SEAT Workshop Service and Repair Manuals

Secondary shaft: disassembly and assembly Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Pliers -A 81124-, see equivalent → Anchor

t	Extractor kit -T20140-, see equivalent → Anchor

t	Extractor kit -U 40100B-, see equivalent → Anchor

t	Kit (case) -U 40200A-, see equivalent → Anchor

t	Kit (case) -U 40300-, see equivalent → Anchor

Remove the outer track of the small roller bearing . –  Place adapter -T20140/1- on clutch casing and screw extractor shaft into adapter -T20140/20- until claws expand. –  Work nut -1- until outer track of small roller bearing is extracted.   Note Release the claws and then expand again after the outer ring has been pulled out by approx.1 mm so that it sits completely on the base of the outer ring.

Install the outer track of the small roller bearing –  Fit the ring under the outer track and using the adapter -U 40200/10- and the adapter -U 40200/12- fit the outer track of the small roller bearing.

Removing the small roller bearing –  Put the layshaft in a vice with protected jaws -A-, so that the 4th gear mesh is facing the vice screw. –  Place adapter -T20022/48- under the roller bearing and tighten hard.

Install the small roller bearing –  Install flat base -U 40100/3- below the 2nd gear mesh, and position adapter -U 40200/19- side A oriented towards roller bearing.

Remove bush for needle bearing, the 4th gear mesh, synchromesh unit of 3rd and 4th gear, 3rd gear mesh and 2nd gear mesh from layshaft. –  Install base plate -U 40100/3- below the gear of the 2ndª gear, and position the adapter -U 40300/2- as shown in the drawing.

Remove bush for gear needle roller bearing, synchromesh unit for 1st and 2nd gear and 1st gear mesh from layshaft. –  Remove the safety ring with pliers -A 81124-.

Removing the large roller bearing

Install the large roller bearing installation position The roller bearing side with the smaller diameter must face adapter -U 40200/18-.

Check wear on synchromesh rings of 1st, 3rd and 4th gears –  Before checking for wear, thoroughly clean the syncromesh rings and their corresponding gears. –  Place synchromesh ring on the corresponding pinion cone. Press the synchromesh ring on the gear, and measure the clearance “a” with a feeler gauge.

Synchroniser ring	Dimension “a” on new synchromesh	Wear limit
1st gear 3rd gear 4th gear	1,0 ... 0.07 in	0.02 in

Removing and fitting the synchromesh unit of 1st and 2nd gears –  To remove the synchromesh assembly of the 1stª and 2ndª gear, remove the springs -1- and move the sliding sleeve -2- completely upwards. Install the 1st and 2nd gear synchromesh unit as follows: –  Place the mobile sleeve -3- on the synchromesh hub -4-, so that the grooves for the locking pins -2- on both components coincide. installation position Install the mobile sleeve on the hub, so that after assembly they are situated with the widest collar on the synchromesh hub -A-, and the outer cogs on the slide -B- facing opposite directions.

Assembling the synchromesh unit of 1st and 2nd gear –  The sliding sleeve must be fitted onto the syncromesh hub. –  Fit locking pieces and install springs separated 120º. The angled ends of the springs must be inside the locking keys.

Installation position of the synchromesh unit of 1st and 2nd gear –  The teeth -1- of the sliding sleeve must be orientated towards the cogs -A- for seating the synchromesh unit of 3rd and 4th gear. –  The collar -2- of the synchromesh hub must be orientated towards the mesh -B- of 1st gear.

Installation of synchromesh assembly of 1st and 2nd gear on layshaft –  Fit the 1st gear synchromesh ring on the 1st gear mesh. –  Place the base plate -U 40100/3- with the adaptor -U 40200/19- with side A facing conical roller bearing. –  Turn syncromesh gear so that the cut-outs coincide with the locking keys. –  After installing the synchromesh unit, fit the safety ring using pliers -A 81124-.

Identification of the rings for the 1stª and 2ndª gear –  Synchronizer ring of the 1st and 2nd gear: 3 grooves -arrows-.

Check 2ndª gear interior synchromesh ring for wear. –  Before checking for wear, thoroughly clean the syncromesh rings and their corresponding gears. –  Place synchromesh ring on the corresponding pinion cone. Press the synchromesh ring on the gear, and measure the clearance “a” with a feeler gauge.

Synchroniser ring	Dimension “a” on new synchromesh	Wear limit
2. Road speed	0,75 ... 0.05 in	0.01 in

Check 2ndª gear exterior synchromesh ring for wear. –  Before checking for wear, thoroughly clean the syncromesh rings and their corresponding gears. –  Place synchromesh ring on the corresponding pinion cone. Press the synchromesh ring on the gear, and measure the clearance “a” with a feeler gauge.

Synchroniser ring	Dimension “a” on new synchromesh	Wear limit
2. Road speed	1,2 ... 0.07 in	0.02 in

Assembly position of the 2ndª gear intermediate synchromesh ring –  The projections -arrows- must be orientated towards the 1st gear mesh -A-.

Assembly position of the 2ndª gear intermediate synchromesh ring –  The projections -arrows 1- of the 2nd gear interior synchromesh ring -A- must fit into the grooves -arrows 2- of the synchromesh ring -B-.

Installation position of 4th gear wheel –  The collar -A- of the 2nd gear mesh must be orientated towards the 1st gear mesh -B-. –  The recesses -arrows- of the 2nd gear mesh -A- must fit into the projections of the intermediate synchromesh ring.

Install bush for gear needle roller bearing –  Install the gear needle roller bearing for the 2nd gear mesh and the end washer. –  Place the base plate -U 40100/3- with the adaptor -U 40200/19- with side A facing conical roller bearing. –  Place the adapter -U 40300/8- with side B orientated towards the bush and the adapter -U 40300/9- between the pressure plate and the adapter -U 40300/8-.

Disassembling and assembling the synchromesh unit of 3rd and 4th gears –  To remove the synchromesh assembly of the 3rdª and 4thª gear, remove the springs -1- and move the sliding sleeve -3- completely upwards. Install the 3rd and 4th gear synchromesh unit as follows: –  Place the mobile sleeve -3- on the synchromesh hub -4-, so that the grooves for the locking pins -2- on both components coincide.

Assembling the synchromesh unit of 3rd and 4th gear –  The sliding sleeve must be fitted onto the syncromesh hub. –  Fit locking pieces and install springs separated 120º. The angled ends of the springs must be inside the locking keys.

Installation position of the synchromesh unit of 3rd and 4th gear –  The bevelled edge collar -arrow- on the synchromesh hub must face the 4th gear mesh.

Installation of synchromesh assembly of 3rd and 4th gear on output shaft –  Place the base plate -U 40100/3- with the adaptor -U 40200/19- with side A facing conical roller bearing. –  Turn syncromesh gear so that the cut-outs coincide with the locking keys.

Identification of synchromesh rings for 3rdª and 4thª gear –  Synchronizer ring of the 3rd and 4th gear: 3 teeth missing -arrows-.

Install bush for gear needle roller bearing –  Place the base plate -U 40100/3- with the adaptor -U 40200/19- with side A facing conical roller bearing. –  Place the adapter -U 40300/8- with side B orientated towards the bush and the adapter -U 40300/9- between the pressure plate and the adapter -U 40300/8-.

Install bush for gear needle roller bearing –  Fit attack washer before installing bush for gear needle roller bearing. –  Place adapter -U 40300/3- with adapter -U 40200/19- with side A orientated towards roller bearing. –  Locate adapter -U 40300/8- with side A facing the bush.