SEAT Workshop Service and Repair Manuals

Dismantling and assembling output shaft for 1st - 4th gear Synchronisation of 1st and 2nd gears for gearboxes manufactured from week 44/09 changed, deviates → Chapter

Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Tappet -T20099 -, see equivalent → Anchor

t	Extractor kit -T20140 -, see equivalent → Anchor

t	Hose clamp -T20141 -, see equivalent → Anchor

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

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

t	Kit (case) -U-40450A -, see equivalent → Anchor

t	Base -A-81124 -, see equivalent → Anchor

t	Hose clamp -T20100 -, see equivalent → Anchor

t	Tappet -U-40404 -, see equivalent → Anchor

Extract the plate washer -A- from the secondary shaft –  Use the installation tool -T20099 -.

Pressing dished washer into output shaft –  Press in the plate washer using the Adapter - U-40200/2 - to the dimension „a“ = 2 mm.

Release the inner ring of roller bearing –  Fit the adapter -U-40100/3- underneath the interior ring of the conical roller bearings. –  Place the adapter -U-40200/1- between the pressure plate and the drive shaft. Use the press.

Insert the inner ring of roller bearing –  Place the installation tool -U-40404- underneath the mobile sleeve. –  Place the assembly inside a vice inserting the clamp -T20141- and the adapter -U-40200/12 -.

Pulling outer race for tapered roller bearing out of gearbox housing –  Extract the outer ring of the conical roller bearing of the gearbox casing using the extractor kit -T20140 - .

Insert the outer ring of the conical roller bearing from the gearbox casing –  Press the clutch housing directly onto the support tool.

Insert the inner ring of roller bearing –  Operate the vice until the shaft securing ring can be fitted. –  Determining the thickness of circlip → Fig. and insert.

Determining the correct thickness securing ring –  Determine the thickest locking ring that will just 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

Fitting the outer ring of the roller bearing into the gearbox casing –  Fit shim under outer race. –  Support the gear housing directly under the outer ring allotment. Dismantle output shaft

Remove the locking collar and synchro-hub for mobile pinion for 3rd and 4th gears and the mobile pinion for 4th gear –  Remove securing ring with pliers -A-81124 - before this.

Press out the locking collar and synchro-hub for mobile pinion for 1st and 2nd gears and the mobile pinion for 2nd gear –  Remove the securing ring. –  Place the adapter -U-40100/3- underneath the synchroniser for the 1st and 2nd gears, release the mobile pinion and the mobile element / synchroniser body together.