SEAT Workshop Service and Repair Manuals

Assembling 1st to 4th gear output shaft - from gearbox date 02 11 9 onwards

Check inner friction surface of 1st gear outer ring and 2nd gear outer ring for wear –  Place inner ring -1- on cone of synchromeshed gear. –  Press outer ring -2- on cone of inner ring. Measure gap size -a- at 3 points offset by 120° using feeler gauge. –  Make a note of average value.

Gap -a-	Installation (new) dimension	Wear limit
1st and 2nd gears	1.00 … 1.80 mm	0.3 mm

Check outer friction surface of 1st gear outer ring and 2nd gear outer ring for wear –  Check inner surface of synchro-ring -arrow- for scoring and radial contact scoring, renew if necessary. –  Place inner ring, outer ring and synchro-ring on cone of inner ring. –  Press on synchro-ring with outer ring whilst turning at same time in order to seat them. –  Measure gap size -a- at 3 points offset by 120° using feeler gauge. –  Make a note of average value.

Gap -a-	Installation (new) dimension	Wear limit
1st and 2nd gears	1.00 … 1.80 mm	0.8 mm

–  Install 2nd gear synchromeshed gear with needle bearing.

Installation of outer ring, inner ring and synchro-ring for 2nd gear –  Place inner ring -A- on synchromeshed gear. Lugs -1- point away from synchromeshed gear. –  Fit outer ring -B-. Lugs -2- engage in notches -3- of synchromeshed gear. –  Fit synchro-ring -C-. Larger notches -4- engage in lugs -1- of inner ring -A-.

Dismantling and assembling locking collars and synchro-hubs of 1st and 2nd gears as well as 3rd and 4th gears 1 -  Spring 2 -  Locking piece 3 -  Locking collar 4 -  Synchro-hub –  Slide locking collar over synchro-hub. In 3rd and 4th gear, wide collar of synchro-hub and, if present, shoulder on locking collar point in one direction. Notches for locking pieces in synchro-hub and locking collar must align.

Assembling locking collars and synchro-hubs for 1st and 2nd gears as well as 3rd and 4th gears Locking collar has been pushed over synchro-hub. –  Insert locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece.

Installation position of locking collar with synchro-hub for 1st and 2nd gears Identification groove -arrow 1- and narrow collar -arrow 2- of synchro-hub face 1st gear.

Pressing on locking collar and synchro-hub for 1st and 2nd gears Pins -A- of synchro-ring engage in notches -B- of synchro-hub. –  Install retaining ring.

Installation of synchro-ring outer ring and 1st gear inner ring –  Insert synchro-ring -A- into synchro-hub. Lugs -1- engage in notches -2- of synchro-hub. –  Insert outer ring -B- into synchro-ring. Lugs -3- point away from synchro-ring. –  Insert inner ring -C- into outer ring. Lugs -4- engage in larger notches -5- of synchro-ring -A-.

Installing synchromeshed gear for 1st gear with needle bearing l  Synchro-ring -1- is located with lugs -arrow A- in notches of synchro-hub -2-. Pins -arrows B- of outer ring engage in notches -arrows C- of synchromeshed gear -3-. –  Install thrust washers for 1st and 4th gears → Item and → Item. –  Install 4th gear synchromeshed gear with needle bearing.

Checking synchro-ring for 4th gear for wear –  Press synchro-ring onto cone of synchromeshed gear and measure gap -a- using feeler gauge.

Gap -a-	Installation (new) dimension	Wear limit
4th gear	1.0 … 1.7 mm	0.5 mm

Installation position of locking collar with synchro-hub for 3rd and 4th gears Wider shoulder of synchro-hub -arrow- faces 3rd gear.

Pressing on synchro-hub with locking collar for 3rd and 4th gears –  Turn synchro-ring so that grooves align with locking pieces. –  Install retaining ring.

Checking inner ring for 3rd gear for wear –  Press inner ring onto cone of synchromeshed gear and measure gap -a- using a feeler gauge.

Gap -a-	Installation (new) dimension	Wear limit
3rd gear	0.75 … 1.25 mm	0.3 mm

Checking synchro-ring for 3rd gear 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 (new) dimension	Wear limit
3rd gear	1.2 … 1.8 mm	0.5 mm

–  Place 3rd gear synchro-ring on locking collar with synchro-hub for 3rd and 4th gears.

Installation position of 3rd gear outer ring Lugs -arrows- face synchro-hub and locking collar -A-.

Installation position of synchro-ring -A- (3rd gear inner ring) Lugs -arrows 1- locate in notches -arrows 2- of synchro-ring -B-.

Installation position of 3rd gear synchromeshed gear Higher shoulder -A- faces 4th gear -B-. Notches in shoulder -arrows- engage in lugs of outer ring → Fig.. –  Install 3rd gear synchromeshed gear with needle bearing.   Note t  Press on tapered roller bearing inner race → Fig.. t  Determine retaining ring for tapered roller bearing inner race → Fig..