SEAT Workshop Service and Repair Manuals

Layshaft: adjustment

Special tools and workshop equipment required

t	Gearbox extractor set -U-40100-

t	Gearbox repair set -U-40200-

t	Universal dial gauge bracket -T20020-

t	Turn torqe checking tool -U-40065-

Adjust the layshaft when one of the following elements have been replaced: l  Gearbox casing l  Clutch housing l  Layshaft l  Layshaft roller bearings Refer to Adjustment chart → Chapter

–  Fit the outer track of the layshaft roller bearings into the clutch housing, with a 0.75 mm thick shim. –  Locate the layshaft in its housing in the gearbox casing. –  Fit the clutch housing onto the gearbox casing and tighten the securing bolts to 25 Nm.

–  Fit tool -T20020- on the gearbox casing with a dial gauge. Locate the end of the dial gauge on thelayshaft. –  Turn the layshaft to settle the roller bearings. –  Adjust the dial gauge to “0” with a pre-tension of 1 mm.   Note! The adjustment to “0”of the dial gauge must be repeated every time the measurement is carried out. Otherwise the dial gauge will not return to the initial position. –  Pull the layshaft in the direction of the dial gauge. –  Take note of the meaurement obtained (e.g. 0.30 mm).   Note! The dial gauge does not return to its initial position. Shim calcuation table The bearing tension is obtained by adding a constant pressure value (0.2 mm) to the average value (0.3 mm) and the thickness of the shim fitted (0.75 mm). Example:

Shim fitted	0.75 mm
+ Average value	0.30 mm
+ Pressure (constant value)	0.20 mm
Thickness of shim necessary	1.25 mm

The following shims are available:

Thickness (mm)	Spare no.
0.70	020 311 391 Q
0.75 0.80 0.85	020 311 391 020 311 391 A 020 311 391 B
0.90 0.95 1.00	020 311 391 C 020 311 391 D 020 311 391 E
1.05 1.10 1.15	020 311 391 F 020 311 391 G 020 311 391 H
1.20 1.25 1.30	020 311 391 J 020 311 391 K 020 311 391 L
1.35 1.40	020 311 391 M 020 311 391 N

If the thickness needed is greater than those indicated on the table, two shims can be used. –  Separate the layshaft. –  Remove the layshaft outer roller bearing track from the clutch housing → Fig., –  Remove the 0.75 mm thick shim from the clutch housing.

–  Fit the outer track of the roller bearing in the clutch housing with the correct shim (in this case 1.25 mm). –  Lubricate the roller bearings with gearbox oil. –  Locate the layshaft in its housing in the gearbox casing. –  Fit the clutch housing onto the gearbox casing and tighten the securing bolts to 25 Nm. –  Check the friction torque →  Checking the friction torque

–  Fit tool -U-40200/9- over the layshaft and the turning torque checking tool -U-40065- over this. The friction torque obtained should be: t  New bearings: 80...160 Ncm t  Used bearings: Mind. 30 Ncm   Note! The bearing must be lubricated with gearbox oil.