SEAT Workshop Service and Repair Manuals

Secondary shaft: dismounting and assembly

t	If new pinions need to be fitted, consult the Identification Initials section, group assignment, reduction ratios, filling amounts → Chapter

t	The secondary shaft must always be adjusted whenever components that may affect the position of the tapered roller bearings have been replaced. Consult the Adjustments chart → Chapter.

1 -	Gearbox casing

2 -	Outer track, tapered roller bearing

q	Detachment → Fig.

q	Assembly → Fig.

3 -	Tapered roller bearing

q	Detach, together with the 1st gear pinion → Fig.

q	Assembly: → Fig.

4 -	Retainer washer

5 -	1st gear pinion

q	Assembly position → Fig.

6 -	Needle bearing for 1st gear pinion

7 -	Inner synchroniser ring for 1st gear

q	Checking for wear → Fig.

q	Check that the flanges show no signs of wear.

q	Assembly position → Fig.

8 -	Outer ring for 1st gear

q	Attach to the synchroniser ring for 1st gear → Item

q	Assembly position → Fig.

q	Replace if there are signs of wear or grooves

9 -	1st gear synchroniser ring

q	Checking for wear → Fig.

q	When assembling, the ring flanges must fit into the housings of the 1st and 2nd gear synchroniser unit → Item

10 -	Guard ring

q	Detachment → Fig.

q	Attachment → Fig.

11 -	Synchroniser unit for 1st and 2nd gears

q	The parts go in pairs.

q	Detachment → Fig.

q	Component assembly → Fig. and → Fig.

q	Assembly → Fig.

12 -

Spring

13 -	Sliding sleeve

14 -	Synchroniser bush

15 -

Cotters

16 -

Spring

17 -	2nd gear synchroniser ring

q	Checking for wear → Fig.

q	Assembly position → Fig.

18 -	Outer ring for 2nd gear

q	Attach to the synchroniser ring → Item

q	Assembly position → Fig.

q	Replace if there are signs of wear or grooves.

19 -	Inner synchroniser ring for 2nd gear

q	Checking for wear → Fig.

q	Check that there are no signs of wear on the flanges.

q	Assembly position → Fig.

20 -	2nd gear pinion

21 -	Guard ring

q	Detachment → Fig.

q	Attachment → Fig.

22 -	Needle bearing for 2nd gear pinion

23 -	3rd gear pinion

24 -	Guard ring

q	Detachment → Fig.

q	Attachment → Fig.

25 -	Guard ring

q	Detachment → Fig.

q	Attachment → Fig.

26 -	4th gear pinion

q	Assembly position: the identification notch must face the tapered unit.

27 -	Secondary shaft

q	If replacing, consult: Adjusting the secondary shaft → Chapter and the Identification Initials section, group assignment, reduction ratios, filling amounts → Chapter.

28 -	Tapered roller bearing

q	Removal → Fig.

q	Attachment → Fig.

29 -	Outer track, tapered roller bearing

q	Removal → Fig.

q	Attachment → Fig.

30 -	Adjusting washer

q	For the secondary shaft.

q	Calculate the thickness → Chapter

31 -	Clutch casing

32 -	Retainer washer

q	The washer step should end up facing the tapered roller bearing.

33 -	Needle bearing bush

q	Detachment → Anchor

q	Assembly → Anchor

34 -	Needle bearing for 5th gear pinion

35 -	5th gear pinion

36 -	5th gear synchroniser ring

37 -

Spring

q	Fit to the 5th gear synchroniser ring.

q	Replace if it shows signs of wear.

38 -	5th gear synchroniser bush

q	Detachment, assembly and adjustment → Chapter onwards

39 -	Sliding sleeve

q	Detachment, assembly and adjustment → Chapter onwards

40 -	Guard ring

Special tools and workshop equipment required

t	Case for extractor tools for gearboxes -U-40100-

t	Replacement parts repair case -U-40200-

t	Pliers for opening elastic rings -A-81124-

Assembling the outer track of the tapered roller bearing –  Using tool -U-40200/10- and -U-40200/11-, attach the outer track of the tapered roller bearing to the gearbox casing.   Note! Attach the 1 mm thick washer between the outer track of the tapered roller bearing and the gearbox casing beforehand.

Removing the tapered roller bearing together with the 1st gear pinion –  Attach tool -U-40100/3- under the 1st gear pinion. –  Set the secondary shaft - with tool -U-40100/3- installed - in a press and detach the bearing together with the 1st gear bearing.

Detaching the guard ring –  Use tool -U-40200/26-.   Caution The guard ring may forcefully spring off during dismounting. Prevent this from happening by placing a cloth or a protective screen behind the secondary shaft. Beware of accidents!

Removing the synchroniser unit for 1st and 2nd gears –  Attach tool -U-40100/3- under the 2nd gear pinion. –  Set the secondary shaft - with tool -U-40100/3- installed - in a press and detach the synchroniser unit for 1st and 2nd gear. –  Detach the needle bearing for the 2nd gear pinion and the 3rd gear pinion.

Removing the tapered roller bearing –  Attach tool -U-40100/4- under the bearing. –  Set the secondary shaft -with tool -U-40100/4- installed- in a press. –  Attach tool -U-40200/4- onto the secondary shaft and take out the bearing.

Assembling the tapered roller bearing –  Attach tool -U-40100/3- under the driving pinion. –  Set the secondary shaft -with tool -U-40100/3- installed- in a press. –  Set tool -U-40200/19- side A onto the bearing and assemble.

Removing the outer track of the tapered roller bearing –  Using tool -U-40100/2-, take the outer track of the secondary shaft tapered roller bearing off the clutch casing.

Assembling the outer track of the tapered roller bearing –  Using tool -U-40200/12- and tool -U-40200/10-, fit the outer track of the tapered roller bearing in the clutch casing.

Attaching the guard ring   Note! Tool -A-81124- can also be used.

Checking the wear on the 1st and 2nd gear inner ring –  Before checking the wear, thoroughly clean the synchroniser rings and their corresponding pinions. –  Attach the inner ring to the 2nd gear pinion cone. Press the synchroniser ring onto the pinion and measure the height “a” with a gauge.

Synchroniser ring	Measurement “a” with the new synchroniser	Limit of wear
1st and 2nd gear	0,75…1,25 mm	0,3 mm

Checking the wear on the synchroniser ring for 1st and 2nd gear –  Before checking the wear, thoroughly clean the synchroniser rings and their corresponding pinions. –  Attach the inner and outer ring to the 2nd gear pinion cone. Press the synchroniser rings onto the pinion and measure the height “a” with a gauge.

Synchroniser ring	Measurement “a” with the new synchroniser	Limit of wear
1st and 2nd gear	1,2…1,8 mm	0,5 mm

Assembly position of the 2nd gear outer, inner and synchroniser rings –  Attach the inner ring -A- to the 2nd gear pinion. Assembly position: The flange elbows -arrow 1- must face the outer ring -B-. –  Attach the outer ring -B-. Assembly position: The flanges -arrow 2- must fit in the pinion grooves -arrow 3-. –  Attach the synchroniser ring -C-. Assembly position: The grooves -arrow 4- fit with the inner ring -A- flange elbows -arrow 1-.

Assembling the components of the 1st and 2nd gear synchroniser unit –  Attach the sliding sleeve -2- to the synchroniser bush -3- so that the grooves on both components coincide. –  Fit the cotters -4- and attach them with the springs -1-, with an offset of 120° between them.

Assembling the components of the 1st and 2nd gear synchroniser unit –  The hooked end of both springs must fit into the corresponding cotter.

Assembling the 1st and 2nd gear synchroniser unit Assembly position: The neck -1- for the pin in the sliding sleeve must face the 1st gear pinion and the teeth -2- of the sleeve must face the 2nd gear pinion. –  Turn the synchroniser ring so that the blocking parts coincide with the housings of the synchroniser ring cotters. –  Use tools -U-40200/20- and -U-40100/3-.

Assembly position of the 1st gear outer ring Assembly position: The flanges -arrows- must face the reverse gear teeth -A-.

Assembly position of the 1st gear inner ring Assembly position: The flanges -1- must sit in the grooves -2- on the synchroniser ring -B-. –  Attach the needle bearing.

Assembly position of the 1st gear inner ring Assembly position: The grooves in the pinion cone -arrows- must fit into the flanges on the synchroniser ring → Fig..

Assembling the tapered roller bearing –  Attach the retainer washer. Use tools -U-40100/3- and -U-40200/15-.