SEAT Workshop Service and Repair Manuals

Disassembly and assembly of the input shaft Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Hot air blower -SAT 1416-, see equivalent → Anchor

t	Push rod -T10080-, see equivalent → Anchor

t	Push rod -T10081-, see equivalent → Anchor

t	Base -T10083-, see equivalent → Anchor

t	Base -T10084A-, see equivalent → Anchor

t	Counterhold -T20003-, see equivalent → Anchor

t	Kit (case) -T20091-, see equivalent → Anchor

t	Hose clamp -T20129-, see equivalent → Anchor

t	Guide socket -T20132-, 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

Extract the input shaft cylindrical roller bearings from the clutch housing –  Extract the bearing using the kit -T20140-. First squeeze the securing ring with pliers. Extraction of the outer roller bearing rings and the bearing bushes using the kit -T20140-

Insert the input shaft cylindrical roller bearing into the clutch housing –  Support the clutch housing on a tubular base directly underneath the bearing bush allotment. –  Fit the cylindrical roller bearing applying the adapter -U-40200/10-. Squeeze the securing ring with pliers while inserting the bearing. –  Remove the pliers before the bearing is in its final installation position. The securing ring should insert into the groove of the clutch pan.

Separate the allotment with grooved ball bearings for the input and secondary shafts –  Engage the 2nd gear by operating the 1st and 2nd gear mobile sleeve into the 2nd gear position. –  Fit the base -T10084A- on the input and secondary shafts. Press the plate to one side until it reaches the input shaft. –  Fit the centering pins of the tool -T10081- into the holes on the input and secondary shafts.

Release the interior ring of the input shaft bearing with the 4th gear mobile pinion –  First release the flexible ring using the adapter -U-40200/26-. –  Fit the kit -T20091- with the adapter -T20091/22- behind the bearing teeth, never behind the engagement teeth of the 4th gear. –  Fit the tool and input shaft assembly in the vice inserting the adapter -U-40200/11- for its removal.   Note When releasing the ring with the 4th gear mesh, ensure they do not fall on the ground (if necessary, ask for the help of a second mechanic).

Release the securing ring -1- from its allotment –  Release the securing ring with adapter -U-40200/26-.   WARNING Avoid the uncontrolled release of the securing ring.

Release the 3rd and 4th gear bushing along with the mobile element –  Once the securing ring is removed, release the 3rd and 4th gear synchroniser body and the mobile pinion for the 3rd gear together.

Disassembling and assembling the mobile element and synchromesh unit of 3rd and 4th gears 1 -  Spring 2 -  Mobile element 3 -  Synchromesh hub 4 -  Locking keyways –  Install the 3rd and 4th gear mobile element as follows: –  Fit the mobile sleeve -2- onto the sychroniser hub liner -3- so that the deepest grooves -arrow A- for the locking pin allotment -4- coincide with the grooves -B- of the mobile element. l  Check that the mobile sleeve -2- moves without difficulty on the sychroniser body -3-

Assemble the locking pins on the hub liner / 3rd and 4th gear sychroniser –  Fit the locking pins in the deepest grooves -arrows- and fit the securing springs off-set by 120º. –  The protruding end of the spring should enter into the hollow locking element.

Installation position of the synchroniser ring on the bushing The groove on the front of the bushing -arrow- should be orientate towards the 4th gear.

Check the synchroniser for damage –  Press the synchroniser ring against the mobile pinion cone and measure the distance “a” with a thickness gauge.

Distance “to”	Assembly level	Wear limit
3, 4. and 6th gear	1,1 ... 1.7 mm	0.5 mm

Insert the synchroniser bushing along with the mobile element for 3rd and 4th gear

Insert the synchroniser bushing securing ring for 3rd and 4th gear

Press in the inner ring -A- for the cylindrical roller bearings onto the input shaft

Determining the correct thickness securing ring –  Fit a securing ring -A- of 2.0 mm in thickness in the groove of the input shaft and press upwards -arrow-. –  Using a thickness gauge, measure the distance between the inner ring -B- and the fitted securing ring -A-. –  Remove the securing ring fitted for taking the measurement. –  Identify the correct securing ring using the table. Selection of the securing ring →  Parts catalogue. Securing rings available

Measured value (mm)	Thickness of the securing ring (mm)	Axial play (mm)
0,05 ... 0,10	2,0	0,05 ... 0,15
0,15 ... 0,20	2,1	0,05 ... 0,15
0,25 ... 0,30	2,2	0,05 ... 0,15
0,35 ... 0,40	2,3	0,05 ... 0,15
0,45 ... 0,50	2,4	0,05 ... 0,10

Fit the input and secondary shafts on the allotment with grooved ball bearings –  Heat the allotment to about 100ºC using the hot air blower -SAT 1416- before fitting to the shafts.

Insert the inner ring -A- for the needle bearing of the 5th gear –  Use the base -T10083- as a support base and press using the clamp -T20129-.

Remove the limit ring from the 5th gear synchroniser body –  Release the tab -A- from the synchroniser body using a screwdriver.

Disassembling and assembling the mobile element/synchroniser body for the 5th gear 1 -  Spring 2 -  Locking keyways 3 -  Synchroniser body. Fitting position: the canal on the front part -arrow A- and the widest edge -arrow B- should be orientated towards 5th gear 4 -  Mobile element 5 -  Limit ring –  Install the 5th gear mobile element as follows: –  Fit the mobile sleeve -4- onto the synchroniser bush -3- so that the deepest grooves -arrow C- for the locking pin allotment -2- coincide with the grooves of the mobile element -D-. l  Check that the mobile sleeve -4- moves without difficulty on the sychroniser body -3-

Assembling the mobile element/synchroniser body for 5th gear –  Fit the locking pins in the narrow groo ves and fit the securing springs off-set by 120º. The protruding end of the spring should enter into the hollow locking element.

Fit the limit ring for the locking elements on the mobile element of 5th gear –  Insert the securing ring for the locking elements onto the guide -T20132-. –  Fit the guide bushing -T20132- along with the securing ring on the synchroniser body with the mobile element for the 5th gear (note the installation position → Fig.) –  Insert the securing ring tabs -1- onto the synchroniser body -2-, pressing downwards, until the securing ring tabs insert in the synchroniser body.