SEAT Workshop Service and Repair Manuals

Dismantling and assembling output shaft for 1st through 4th gears 1st/2nd gear synchronisation modified from gearbox date 02 11 9, differentiation → Chapter

Special tools and workshop equipment required

t	Pressure plate -VW 401-

t	Pressure plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 408A-

t	Press tool -VW 412-

t	Tube -VW 415A-

t	Support plate -VW 309-

t	Support clamp -VW 313-

t	Gearbox support -VW 353-

t	Thrust piece -VW 431-

t	Thrust piece -VW 433-

t	Thrust piece -VW 454-

t	Thrust piece -VW 512-

t	Tube -VW 516-

t	Tube -VW 519-

t	Multipurpose tool -VW 771-

t	Support plate -VW 801-

t	Thrust plate -40-105-

t	Drift sleeve -40-20-

t	Drift sleeve -40-21-

t	Thrust piece -2050-

t	Supplementary set for engine and gearbox support -VW 540/1 B-

t	Tapered roller bearing puller -V.A.G 1582-

t	Adapter -V.A.G 1582/7-

t  -1-Internal puller -Kukko 21/7- t  -1-Internal puller -Kukko 21/8- t  -2-Puller -Kukko 18/2- t  -3-Splitter -Kukko 17/2- t  -4-Counter support -Kukko 22/2-

Pulling dished washer -A- out of output shaft

Pressing dished washer into output shaft Dimension “a” = 2 mm

Press off tapered roller bearing inner race on side facing clutch housing A -  Splitter, 22 … 115 mm, e.g. -Kukko 17/2-

Press on tapered roller bearing inner race on side facing clutch housing

Pulling tapered roller bearing outer race out of clutch housing A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 56 … 70 mm, e.g. -Kukko 21/8-

Pressing tapered roller bearing outer race into clutch housing –  Support clutch housing with drift sleeve -40-20- directly below bearing support.

Pull off tapered roller bearing inner race on side facing gearbox housing Before setting up tapered roller bearing puller: –  Remove retaining ring for tapered roller bearing inner race on side facing clutch housing. –  Insert press tool -VW 431- into output shaft and place thrust plate -40-105- on that.

Press on tapered roller bearing inner race on side facing gearbox housing –  Determine and install retaining ring → Fig..

Determining thickness of retaining ring –  Determine thickest retaining ring which will still fit and install it.   Note Allocate retaining rings using → Electronic parts catalogue (ETKA). The following retaining rings are available:

Thickness (mm)
1.79	1.83	1.86	1.89
1.92	1.95	1.98

Pulling outer race for tapered roller bearing out of gearbox housing A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 46 … 58 mm, e.g. -Kukko 21/7-

Pressing tapered roller bearing outer race into gearbox housing –  Fit shim under outer race. –  Support gearbox housing with thrust piece -2050- below bearing support. Dismantle output shaft.   Note Pull off tapered roller bearing inner race on side facing clutch housing → Fig..

Pulling off synchro-hub and locking collar for 3rd and 4th gears with synchromeshed gear for 4th gear –  First remove retaining ring. A -  Puller, e.g. -Kukko 18/2- B -  Splitter, 22 … 115 mm, e.g. -Kukko 17/2-

Pressing off locking collar and synchro-hub for 1st and 2nd gears After removing retaining ring, press off synchromeshed gear for 2nd gear together with locking collar and synchro-hub.