SEAT Workshop Service and Repair Manuals

Drive shaft (drive pinion), disassembly and assembly   WARNING When assembling the pinion shaft, this must be adjusted as well as the crown wheel → Chapter   Note Removing and installing the gear wheels for 3rd to 6th gear and the reverse selector gear is described in chapter on dismantling and assembling gearbox → Chapter. Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter

Special tools and workshop equipment required

t	Clutch press -VW 401-, see equivalent → Anchor

t	Clutch press -VW 402-, see equivalent → Anchor

t	Die -VW 407-

t	Die -VW 412-

t	Tube element -VW 415 A-

t	Tube element -VW 519-

t	Press tool -40 - 21-

t	Thrust blocks -2050-

t	Thrust pad -3062-

t	Thrust blocks -3118-

t	Slotted nut wrench -3155-

t	Sleeve -3144-

t	Assembly tool -3253-

t	Tube for wheel bearing -3345-

t	Hot air blower -V.A.G 1416-, see equivalent → Anchor

t	-1-Inside extractor -Kukko 21/8-, see equivalent

t	-3-Splitter -Kukko 17/2-

t	-4-Support bracket -Kukko 22/2-, see equivalent

t

Calibre

Pulling outer race for tapered roller bearing out of gearbox housing –  Removing differential → Chapter. –  Fit thrust piece -2050- with the large diameter pointing towards the outer race. –  Fit threaded spindle and thrust pad of assembly tool - 3253- with thrust plate -VW 401- onto gearbox housing. The outer race will be pulled out of the gearbox housing when the nut is tightened.

Heating gearbox housing in order to fit tapered roller bearing outer race –  Heat gearbox housing in area of bearing seat for approx. 15 minutes, to approx. 100°C, with hot air blower -V.A.G 1416-.

Fitting the outer ring of the roller bearing into the gearbox casing –  Insert outer race only after heating gearbox housing and push into position under workshop press until heat exchange has taken place.

Pulling tapered roller bearing outer race out of bearing housing A  -  Support bracket, for example -Kukko 22/2- or extractor kit -T20140- B  -  Inside extractor 56 - 70 mm, for example -Kukko 21/8- or adapter -T20140/38-

Pressing tapered roller bearing outer race into bearing housing Support bearing housing with sleeve -3144- directly below bearing mounting. –  Press in outer race until limit stop.

Pressing off thrust washer for reverse selector gear A  -  Splitter 22...115 mm, e.g. -Kukko 17/2-   Note Fit splitter-A- below thrust washer, and not below circlip. –  Then detach circlip below thrust washer.

Pressing off tapered roller bearing inner race with 2nd speed selector gear A  -  Splitter 22...115 mm, e.g. -Kukko 17/2-   Caution When pressing off, make sure that only the gear teeth (driving teeth) of the selector gear and not the dog teeth contact the splitter -A-. Otherwise the dog teeth will be damaged. –  Remove circlip for tapered roller bearing inner race.

Pressing off 1st and 2nd gear synchronising hub –  Remove circlip before pressing off. –  Press synchronising hub off with 1st speed selector gear

Pressing off tapered roller bearing inner race –  Remove circlip before pressing off. –  The outer race of the tapered roller bearing -arrow- must be fitted prior to pressing off the inner race.

Inserting the inner ring of the roller bearing by pressure –  Heat inner race to approx. 100 °C and press on.   WARNING Determine thickness of required circlip → Fig. and install circlip.

Determining thickness of circlip –  Determine the thickest circlip that will just fit and install it. For Part No. refer to → Spare parts catalogue.   Note The thickness of the circlips for the synchronising hubs and individual gear wheels must also be determined as shown for the tapered roller bearing. Overview for installation position of circlips → Fig.

Installation position of circlips The required circlips for the inner races of the tapered roller bearings, the synchronising hubs and individual gear wheels should be selected as shown in → Fig.. t  Circlip -1- secures the tapered roller bearing inner race.

Retaining ring thickness (mm)
2,50	2,56	2,62
2,53	2,59	2,65

t  Circlip -2- secures the 1st and 2nd gear synchronising hub. Distinguishing feature: Colour blue

Retaining ring thickness (mm)
1,90	2,02	2,14
1,93	2,05	2,17
1,96	2,08
1,99	2,11

t  Circlip -3- secures the tapered roller bearing inner race.

Retaining ring thickness (mm)

3,50

t  Circlip -4- secures thrust washer for reverse selector gear.

Retaining ring thickness (mm)

3,50

t  Circlip -5- secures the 3rd gear wheel.

Retaining ring thickness (mm)
1,90	1,98	2,06
1,94	2,02	2,10

t  Circlip -6- secures the 6th gear wheel.

Retaining ring thickness (mm)
1,90	2,02	2,14
1,93	2,05	2,17
1,96	2,08	2,20
1,99	2,11

–  Determine circlips according to table: For Part numbers refer to → Spare parts catalogue.

Installation position of synchro-rings for 1st and 2nd gear:   Note If components are not to be replaced, ensure that these are allocated to their corresponding gears. –  Fit inner ring -2- onto selector gear -1-. –  Fit intermediate ring -3-. Lug -B- must be inserted into recess -A-. –  Synchro-ring -4- fitted. Guide lugs -C- through recess -arrow-.

Checking 1st gear inner ring for wear –  Check outer contact surface -arrow- for scoring or visible traces of wear and renew if necessary. –  Press inner ring onto chamfer on selector gear and measure gap -a- using a feeler gauge.

Gap -a-	As-new installation value	Wear limit
1. Gear - inner ring	1.2 ... 2.0 mm	0.6 mm

Checking 1st and 2nd gear intermediate ring for wear –  Check inner friction surface of synchro-ring for scoring or visible traces of wear and renew if necessary. –  Press inner ring, intermediate ring and synchro-ring onto chamfer on selector gear and measure gap -a- using a feeler gauge.

Gap -a-	As-new installation value	Wear limit
1. and 2nd gear	1,4 ... 2.0 mm	0.8 mm

Pressing on 1st and 2nd gear synchronising hub t  Installation position: Higher inside collar faces 2nd gear. l  The lugs of 1st gear synchro-ring and recesses on synchronising hub must align -arrow- when pressing on.

Assembling 1st and 2nd gear locking collar/synchronising hub –  Fit locking pieces -arrows A- into mounted synchronising hub -1-. –  Fit locking collar -2- onto synchronising hub so that the wide splines of locking collar and synchronising hub -arrow B- coincide. –  Install circlip for 1st and 2nd gear synchronising hub. –  Install 2nd speed selector gear with needle bearing and synchro-rings.

Inserting the inner ring of the roller bearing by pressure –  Fit circlip for tapered roller bearing inner race onto pinion shaft. l  Shoulder of tube -VW 415 A- faces inner race -arrow-. Then check axial play of 1st speed and 2nd speed selector gears → Fig. and → Fig..

Checking axial play of 1st speed selector gear –  Press 1st speed selector gear -2- in direction of -arrow A- as far as the stop. –  Measure the distance between the 1st speed selector gear -2- and synchro-ring -3- using a feeler gauge-1-. Example: 2.55 mm –  Now press 1st speed selector gear -2- in direction of 2nd speed selector gear -4-. –  Measure the distance again between the 1st speed selector gear -2- and synchro-ring -3- using a feeler gauge-1-. Example: 2.15 mm l  The difference between the two measured values must be between 0.20 ... 0.50 mm.

Checking axial play of 2nd speed selector gear –  Check axial play between 2nd speed selector gear -2- and inner race of tapered roller bearing -3- using a feeler gauge-1-. l  The play must be 0.20 ... 0.50 mm.

Pressing on thrust washer for reverse selector gear –  Fit circlip -B- onto output shaft. –  Press on thrust washer -A- until it makes contact with circlip.