SEAT Workshop Service and Repair Manuals

Secondary shaft: adjustment

Special tools and workshop equipment required

t	Case for extractors for gearboxes -U-40100-

t	Replacement parts repair case -U-40200-

t	Multi-purpose stand for the comparator -T20020-

t	Turning torque tester -U-40065-

Adjust the secondary shaft when any of these parts has been replaced: l  Gearbox casing. l  Clutch casing. l  Secondary shaft (front pinion/crown unit). l  Tapered roller bearing in the secondary shaft. In order to avoid unnecessary adjustment work, consult the Adjustment Chart → Chapter

–  Assemble the external track for the tapered roller bearing for the secondary shaft, in the clutch casing, with an adjustment washer 0.75 mm thick, using tool -U-40200/10- and the tool -U-40200/12-. –  Place the secondary shaft into its housing in the gearbox casing. –  Assemble the clutch casing to the gearbox casing and screw in the securing bolts. t  Tightening torque: 25 Nm

–  Put tool -T20020- with a tester on the gearbox casing. Set the tip on the secondary shaft. –  Give the primary shaft a few turns to seat the tapered roller bearings. –  Adjust the comparator to “0” with a pre-set pressure of 1mm.   Note! The adjustment of the tester to “0” must be repeated each time the measurement is done. If not, the tester will return to the initial position. –  Pull the secondary shaft in the direction of the tester. –  Write down the reading obtained in the comparator (Example, 0.30 mm).   Note! The tester does not return to the initial position. Calculating the adjustment washer. Calculating the adjustment washer The thickness of the adjustment washer to be mounted is found by adding the reading values obtained with the comparator, the thickness of the adjustment washer mounted earlier and a set value. Example:

Reading obtained with the comparator	0,30 mm
Thickness of the washer already mounted	0,75 mm
Set value	0,20 mm
Thickness of the adjustment washer needed	1,25 mm

The adjustment washer needed is to be found using the following Table.

Thickness (mm)	Parts 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

The diversity of the adjustment washers available allows you to find exactly the right thickness needed to perform a proper adjustment of the secondary shaft. In the event that the thickness of the adjustment washer needed is greater than the thicknesses that appear in the Table, two adjustment washers may be mounted, the thicknesses of which added together correspond to the given value. –  Once the adjustment washer that is needed has been found, remove the comparator. –  Take out the bolts securing both casings and detach the clutch casing. –  Separate the secondary shaft.

–  Remove the outer track of the tapered roller bearing of the secondary shaft from the clutch casing using tool -U-40100/2-. –  Remove the washer that is 0.75 mm thick. –  Put the adjusting washer with the calculated thickness (in this case, 1.25 mm) in the outer track of the secondary shaft tapered roller bearing housing.

–  Using tool -U-40200/10- and tool -U-40200/12-, attach the outer track of the secondary shaft tapered roller bearing with a 0.75 mm thick adjusting washer to the clutch casing. –  Lubricate the tapered roller bearings with oil for gearboxes. –  Put the secondary shaft into its housing in the gearbox casing. –  Attach the clutch casing to the gearbox casing and screw in the securing bolts. t  Tightening torque: 25 Nm –  Check the friction torque. Checking the friction torque

–  Attach the turning torque tester -U-40065- to tool -U-40200/9- and this to the secondary shaft. The resulting friction torque should be: New bearings: 80…160 Ncm Used bearings: At least 30 Ncm