SEAT Workshop Service and Repair Manuals

Secondary shaft for 1st to 4th gear: adjustment The secondary shaft should always be readjusted when any of the following components have been changed: t  Gearbox t  clutch housing t  Secondary shaft for 1ª to 4ª gear t  Conical roller bearings Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Torque wrench kit -SAT 8010-, see equivalent → Anchor

t	Bracket -T20020-, see equivalent → Anchor

t	Extractor kit -T20140-, see equivalent → Anchor

t	Kit (case) -U 40200A-, see equivalent → Anchor

l  The gearbox is secured on the assembly stand. l  The sealing surfaces of both the gearbox and the clutch should be free of sealant. l  To carry out the measurement, only fit the shaft to be measured.

–  Insert the roller bearing outer ring with a 1.70 mm shim into the gearbox housing; to do this support the housing by fitting the kit -U 40200A- underneath the bearing allotment. –  Insert the secondary shaft for the 1st to 4th gears into the clutch housing.

–  Fit the gearbox housing over and tighten the bolts -A- and -B- diagonally with the correct tightening torque.

–  Fit the support -T20020- and measurement tools securing them to the clutch housing with the bolt -arrow-. –  Put the dial gauge (3 mm range) to “0” with a pretension of 1 mm. –  Loosen, diagonally, the bolts securing the clutch housing to the gearbox until the gearbox housing or the secondary shaft may be lifted. –  Read the value indicated by the dial gauge and note it (in the example: 0.14 mm).   Note When loosening the bolts securing the clutch housing to the gearbox, no value is indicated on the dial gauge, the shim of 1.95 mm or that of 2.20 mm must be fitted to make the measurement. Determining thickness of shim: The specified bearing preload is attained by subtracting the measured value (0.14 mm) from the inserted shim (1.70 mm) and adding a constant value for preload (0.20 mm).

Example:
Shims fitted	1,70 mm
- measured value	0,14 mm
+ Pressure (const. value)	0,20 mm
Thickness of shim	1,76 mm

–  Determine shim thickness using the table; part number → Current parts catalogue. The following shims are used:

Thickness of shims → Note in mm
1,45	1,70	1,95	2,20
1,50	1,75	2,00	2,25
1,55	1,80	2,05
1,60	1,85	2,10
1,65	1,90	2,15

1)  The existence of different tolerances allows the necessary shim thickness to be selected precisely.

–  Take off gearbox housing and pull tapered roller bearing out of gearbox housing. l  Extraction of the outer roller bearing rings and the bearing sockets using the extractor kit -T20140-. –  Remove the shim fitted (1.70 mm) from the gearbox housing.

–  Insert the roller bearing outer ring with the shim of the determined thickness (in this case 1.75 mm) into the gearbox housing; to do this support the housing directly underneath the bearing allotment.

Measurement l  The required shim should already be fitted –  Fit the support -T20020- and measurement tools securing them to the clutch housing with the bolt -arrow-. –  Put the dial gauge (3 mm range) to “0” with a pretension of 1 mm. –  Loosen, diagonally, the bolts securing the clutch housing to the gearbox until the gearbox housing or the secondary shaft may be lifted. l  The gauge should now be properly selected with levelling dosc worth a value of 0.15 ... show 0.25 mm.