SEAT Workshop Service and Repair Manuals

Disassembly and assembly of the input shaft Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Pressure plate -VW 401-, see equivalent → Anchor

t	Pressure plate -VW 402-, see equivalent → Anchor

t	Terminal crimper -VW 407-, see equivalent → Anchor

t	Terminal crimper -VW 412-, see equivalent → Anchor

t	Tube element -VW 415 A-

t	Tube element -VW 422-

t	Spacer bush -VW 472/2-

t	Pipe section -VW 516-, see equivalency → Anchor

t	Locking plate -30-23-

t	Press tool -30-100-

t	pressure tool -T10080-

t	pressure tool -T10081-

t  Dished washer -T10083/1-

t	Base for fitting -T10083-

t	Tightening plate -T10084 A-

t	-1-Interior extractor -Kukko 21/5-

t	-4-Support bracket -Kukko 22/2-

Extract the roller bearing from the clutch housing –  On removing the roller bearing, press the safety ring -arrow- with pliers -C-. A  -  Counter-support, e.g. -Kukko 22/1- B  -  Internal remover 30... 37 mm, e.g. -Kukko 21/5-

Pressing cylindrical roller bearing into clutch housing –  Support the clutch casing by placing the tubular section -VW 415 A- (not seen in the fig.) directly below the allotment. –  On fitting the roller bearing, press the safety ring -arrow- with pliers -A-. –  Remove the pliers before the roller bearing is in the assembly position. The securing ring should insert into the groove of the clutch housing.

Detach the allotment with grooved ball bearings –  Slide locking collar for 1st and 2nd gear onto 2nd gear. –  Slide in thrust plate -T10084 A- sideways until it contacts input shaft. –  Remove the securing ring.

Release the inner ring of the roller bearing –  Press off roller bearing inner race together with thrust washer, 4th speed selector gear with needle bearing, locking collar and synchronising hub for 3rd and 4th gear and 3rd speed selector gear.

Dismantling and assembling 3rd and 4th gear locking collar and synchro-hub 1 -  Spring 2 -  Mobile element 3 -  Synchro-hub 4 -  Locking piece –  Slide locking collar over synchro-hub. Deeper notches -arrow A- for locking pieces in synchro-hub and notches -arrow B- in locking collar must align.

Assemble the mobile sleeve and synchromesh unit for 3rd and 4th gear l  The mobile element is on the synchromesh body. –  Fit the locking elements in the deepest grooves -arrows- and fit the elastic rings off-set by 120º. The right angled end of the elastic rings should hook on the lower hollow section of the locking part.

Installation position of locking collar with synchro-hub for 3rd and 4th gears The groove on the front -arrow- should face towards 4th gear.

Checking synchro-ring for wear –  Press the synchromesh ring against the mobile pinion cone and measure the distance -a- with a thickness gauge.

Gap -a-	Installation dimension	Wear limit
3., 4., 5. and 6th gear	1.1 ... 1.7 mm	0.5 mm

Pressing on synchro-hub with locking collar for 3rd and 4th gears Installation position: Wide shoulder faces 3rd speed selector gear

Pressing on sleeve -A- for 4th gear needle bearing –  After installing the sleeve -A-, mount the needle bearing and the mobile pinion of 4th gear together with the thrust ring.

Insert the inner ring -A- of the cylindrical roller bearing.

Determining thickness of circlip –  Insert a 2.0 mm thick retaining ring -A- in groove of input shaft and press upwards -arrow-. –  Measure the distance between the inner ring -B- and the securing ring fitted -A- using a thickness gauge -C- . –  Remove retaining ring used for measuring purposes. –  Select circlip from table.   Note See → Electronic catalogue of spare parts „ETKA“ to allocate securing rings. The following retaining rings are available:

Measured value (mm)	Retaining ring thickness (mm)	Axial play (mm)
0,05 … 0,14	2,0	0,05 … 0,15
0,15 … 0,24	2,1	0,05 … 0,15
0,25 … 0,34	2,2	0,05 … 0,15
0,35 … 0,44	2,3	0,05 … 0,15
0,45 … 0,51	2,4	0,05 … 0,10

Press bearing mounting with deep groove ball bearing onto input shaft and output shaft.   Note

t  Due to different spline heights, dimension -a-, output shafts of individual gearboxes have different lengths (shown here with shafts installed). t  To ensure that bearing support is always evenly pressed onto shafts, it is necessary for shafts always to be inserted evenly into thrust block -T10083-. t  If necessary, insert a shim -T10083/1- (3 mm thick) into fitting hole for input shaft → Fig.. t  This is the reason why dimension -a- for output shaft teeth must be measured.

Dimension -a- = 30.6 mm

Insert shim -T10083/1- ⇒ next figure.

Fit shim -T10083/1-.

Fit the allotment with grooved ball bearings –  Before fitting, heat the allotment to a max. of 100 °C.   WARNING Wear protective gloves!

Pressing on sleeve -A- for 5th gear needle bearing

Dismount and assemble mobile element and synchromesh body of 5th / 6th gear 1 -  Spring 2 -  Mobile element 3 -  Synchro-hub 4 -  Locking piece –  Slide locking collar over synchro-hub. Deeper notches -arrow A- for locking pieces in synchro-hub and notches -arrow B- in locking collar must align.

Insert the unit comprising locking collar and synchromesh body of 5th / 6th gear. l  The mobile element is on the synchromesh body. –  Fit the locking elements in the deepest grooves -arrows- and fit the elastic rings off-set by 120º. l  The right angled end of the elastic rings should hook on the lower hollow section of the locking part.