SEAT Workshop Service and Repair Manuals

Secondary shaft for 5th/6th and reverse gear: dismantling and assembling

Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Kit (case) -T20022-, see equivalent → Anchor

t	Extractor kit -T20140-, see equivalent → Anchor

t	Pressure tool -T20141-, see equivalent → Anchor

t	Extractor kit -U 40100B-, see equivalent → Anchor

t	Kit (case) -U 40200A-, see equivalent → Anchor

t	Push rod -U-40404-, see equivalent → Anchor

Extract the outer ring of roller bearing socket   Note Once the part is extracted, check if the shim is damaged and change it if necessary. Extraction of the outer roller bearing rings and the bearing sockets using the extractor kit -T20140-.

Insert the outer ring of the conical roller bearing into the clutch housing. –  Fit the shim underneath the outer ring.

Extract the inner ring of the conical roller bearing –  Remove the securing ring. –  Before fitting the extractor, fit the adapter -U-40200/1- as a base onto the secondary shaft.

Extract the mobile element/synchroniser body for the 5th and 6th gear along with the 6th mobile pinion –  Remove the securing ring before releasing. –  The adapter -U-40100/3- must rest on the mobile pinion of the 6th gear.

Release the sleeve from above the reverse gear mobile pinion –  Remove the securing ring before releasing.

Release the synchroniser body for the reverse gear –  Remove the mobile element from the synchroniser body before installing the U 40100/3.

Extract the inner ring of the conical roller bearing

Installation position of the synchroniser body for the reverse gear l  The limit -arrow A- of the reverse gear mobile element should point to the secondary shaft teeth -arrow B-

Insert the synchroniser body for the reverse gear –  Fit the mobile element with the synchroniser ring before fitting the reverse gear mobile pinion.

Insert the sleeve -A- Fitting position: the wide collar must point towards the mobile pinion of the reverse gear. –  Then fit the securing ring.

Check 5th and 6th gear synchroniser ring for wear. –  Press the synchroniser ring against the mobile pinion cone and measure the distance -a- with a thickness gauge.

Assembly level	Wear limit
1.0 … 1.7 mm	0.5 mm

Disassembly and assembly of the mobile element/synchroniser body for the 5th and 6th gear –  To disassemble, the springs must be removed -1-. 2 -  Locking element 3 -  Moveable sleeve 4 -  Synchroniser body –  To assemble, fit the mobile element onto the synchroniser body. l  Fitting position: the smaller recesses -arrow A- in the synchroniser body must coincide with the recesses -arrow B- of the mobile element

Assemble the mobile element/synchroniser body of the 5th and 6th gear l  The mobile element is fitted onto the synchroniser body –  Fit locking pieces and install springs offset by 120º. l  The protruding end of the spring should enter into the locking element allotment

Insert mobile element/synchroniser body of the 5th and 6th gear –  Then fit the securing ring.

Fit the inner ring of the conical roller bearing –  Determine the thickness of the securing ring → Fig. and fit it.

Determining the correct thickness securing ring –  Determine the thickest securing ring “as precisely as possible” according to part number → Parts catalogue and fit it.

Fit the inner ring of the conical roller bearing

Remove the outer ring of the conical roller bearing from the gearbox casing

Insert the outer ring of the conical roller bearing into the gearbox housing. –  Support the gearbox housing fitting the adapter -U-40200/14- directly underneath the bearing allotment.