SEAT Workshop Service and Repair Manuals

Dismantling and assembling output 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 402-, see equivalent → Anchor

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

t	Tube element -VW 415 A-

t	pressure tool -VW 432-

t	Press tool -30-100-

t  -1-Interior extractor -Kukko 21/5- t  -4-Support bracket -Kukko 22/1-

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.

Release the securing ring -1- from its slot A  -  Wear protective gloves!   WARNING Ensure retaining ring does not spring out uncontrolled.

Press out the mobile sleeve / synchroniser body of 1st and 2nd gear –  After removing retaining ring, press off synchromeshed gear for 2nd gear together with locking collar and synchro-hub.

Installation position of 3rd and 4th gear wheel –  Fit 4th gear wheel -A- onto output shaft. Installation position: The collar -arrow 1- should face towards the 3rd gear pinion -B-. –  Fit the securing rings -2- and -3-. –  Fit 3rd gear wheel -B- onto output shaft. Installation position: The collar -arrow 2- should face towards the 4th gear pinion -A-. –  Fit the securing ring -1-.

Checking inner ring for 1st and 2nd gear for wear –  Press inner ring onto cone of synchromeshed gear and measure gap „a“ using a feeler gauge.

Gap „a“	Installation dimension	Wear limit
1st and 2nd gears	0.75...1.25 mm	0.3 mm

Checking 1st and 2nd gear synchro-rings for wear –  Press synchro-ring, outer ring and inner ring onto cone of synchromeshed gear and measure gap „a“ using a feeler gauge.

Gap „a“	Installation dimension	Wear limit
1st and 2nd gears	1.2 ... 1.8 mm	0.5 mm

Installation position of outer ring, inner ring and synchro-ring for 2nd gear –  Place inner ring -A- on synchromeshed gear for 2nd gear. The slanted reinforcements -arrows 1- should face the outer ring -B-. –  Fit the outer ring -B-. The tabs -arrows 2- insert into the recesses -arrows 3- of the mobile pinion. –  Fit the synchroniser ring -C-. Notches -arrow 4- engage in lugs -arrow 1- of inner ring -A-.

Disassembly and assembly of the mobile element / synchroniser body unit for 1st and 2nd gear 1 -  Spring 2 -  Mobile element 3 -  Synchro-hub 4 -  Locking piece –  Slide locking collar over synchro-hub. Installation position: After assembling the unit, the groove of the front part -arrow A- and the highest collar -arrow B- of the synchromesh body should face the exterior cogs of the mobile element -arrow C-. Deeper notches -arrow D- for locking pieces in synchro-hub and notches -arrow E- in locking collar must align.

Assemble the mobile gearshift sleeve / synchroniser body unit of 1st and 2nd 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.

Pressing on locking collar and synchro-hub for 1st and 2nd gears Installation position: Groove for selector fork in locking collar points towards 1st gear; reverse gear splines point towards 2nd gear. –  Turn synchro-ring so that grooves align with locking pieces.

Fit retaining ring. –  Fit the 1st gear securing ring on the mobile sleeve / synchromesh assembly.

Installation position of outer ring for 1st gear The tabs -arrows- point towards the teeth of the reverse gear.

Installation position of 1st gear inner ring -A- The tabs -arrows 1- insert into the recesses -arrows 2- of the synchromesh ring -B-.

Installation position of 1st speed selector gear The highest collar -A- should face 2nd gear -B-. Notches in shoulder -arrows- engage in lugs of outer ring → Fig..