Workshop Manuals Factory service & repair SEAT
SEAT Leon Mk101 · Power transmission
01 · Transmission

Secondary shaft: Disassembling and assembling

Make
SEAT
Model
Leon Mk1
Section
02R, 5-speed manual transmission › Gearbox,mechanics,gears,shafts,internal operation › Secondary shaft: Disassembling and assembling
Power transmissionSecondary shaft: Disassembling and assembling
   
Secondary shaft: assembly overview
Secondary shaft: Disassembling and assembling – SEAT Leon Mk1  Note
t  When installing new gears or a output shaft, see technical data → Chapter, Identification letters, group allocation, ratios, filling quantities
t  If the layshaft or roller bearings are replaced, the layshaft must be adjusted → Chapter
t  The layshaft must be adjusted whenever elements have been replaced which could affect the position of the roller bearings. Refer to Adjustment chart → Chapter
Secondary shaft: Disassembling and assembling – SEAT Leon Mk1
1 - Conical hexagon bolt
q   25 Nm + 90°
q   4x
q   To secure the bearing housing
2 - clutch housing
q   Repairing → Chapter
3 - Shim
q   For secondary shaft
q   Determining thickness → Chapter
4 - Small tapered roller bearing outer race
q   Removing → Fig.
q   Installing → Fig.
5 - Small roller bearing
q   Removing → Fig.
q   Installing → Fig.
6 - Output shaft
q   Paired with final drive gear wheel. Always renew as a set.
q   In case of replacement → Chapter, Code letters, group allocation, ratios, capacities
q   Adjusting → Chapter
7 - Large roller bearing
q   Removing → Fig.
q   Installing → Fig.
8 - Sealing ring
q   4x
q   Always replace
q   For the securing bolts of the bearing housing → Item
9 - Bearing housing
q   With large primary shaft bearing outer track → Item
q   The external track should only be replaced together with the large roller bearing and the bearing housing
10 - Thrust washer
q   Shoulder of thrust washer faces tapered roller bearing
11 - 1st speed selector gear
q   Before fitting the gear pinion of the 1st gear, install the thrust washer → Item
12 - Needle bearing
q   for the 1st gear mobile pinion
13 - Synchro-ring for 1st gear
q   Identification → Fig.
q   Checking for wear → Fig.
q   Check that the tabs show no signs of wear
14 - Synchronising hub for 1st and 2nd gear
q   Removing → Fig.
q   Dismantling → Fig.
q   Assembly of components → Fig. and → Fig.
q   Installation position → Fig.
q   Installing → Fig.
15 - Circlip
q   Use pliers -A 81124- to remove the safety ring.
q   Always replace
16 - Outer synchroniser ring for 2nd gear
q   Identification → Fig.
q   Checking for wear → Fig.
q   Fitting position: the grooves in the synchromesh ring must fit with the pins in the synchromesh assembly of 1st and 2nd gear → Item
17 - Middle synchroniser ring for 2nd gear
q   Fit into the outer synchromesh ring of the 2nd gear → Item
q   Installation position → Fig.
q   Replace if it shows signs of wear or grooves
18 - Inner synchroniser ring for 2nd gear
q   Identification → Fig.
q   Checking for wear → Fig.
q   Check that the tabs show no signs of wear
q   Installation position → Fig.
19 - 2nd speed selector gear
q   Installation position → Fig.
20 - Needle bearing
q   For 2nd gear mobile pinion
21 - Thrust washer
22 - Needle bearing bush
q   Remove together with the mobile pinion of 2nd gear → Fig.
q   Installing → Fig.
23 - Needle bearing
q   For the 3rd gear selector gear
24 - 3rd speed selector gear
25 - Synchromesh ring 3rd gear
q   Identification → Fig.
q   Checking for wear → Fig.
26 - Synchromesh body of 3rd and 4th gear
q   Removing → Fig.
q   Dismantling → Fig.
q   Assemble → Fig. and → Fig.
q   Installation position → Fig.
q   Installing → Fig.
27 - Needle bearing bush
q   Remove together with the synchromesh assembly of the 3rd and 4th gear → Item
q   Installing → Fig.
28 - Needle bearing
q   For 4th gear mobile pinion
29 - Synchroniser ring for 4th gear
q   Identification → Fig.
q   Checking for wear → Fig.
30 - 4th speed selector gear
31 - Thrust washer
32 - Needle bearing
q   For secondary shaft
q   Removing and fitting → Chapter, Gearbox housing and clutch housing: repairs
33 - Gearbox
34 - Needle bearing bush
q   Removing → Fig.
q   Installing → Fig.
35 - 5th gear mobile pinion
q   Installation → Chapter, Gearbox housing cover and 5th gear: Removing and installing
36 - Dished washer
q   Fitting position: The concave side should be facing the selector gear for the 5th gear
37 - Attachment bolt of 5th gear mobile pinion
q   The screw head incorporates a housing for the plate spring → Item
q   Fitting → Chapter, Gearbox housing cover and 5th gear: Removing and installing

   

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