SEAT Workshop Service and Repair Manuals

Secondary shaft for 1st to 4th gear: Assemble gearboxes manufactured to week 44/09

Check the wear of the inner ring of the 1st, 2nd and 3rd gear –  Press inner ring onto cone of synchromeshed gear and measure gap -a- using a feeler gauge.

Dimension -a-	Installation depth	Wear limit
1., 2. 3rd gears	0.75 ... 1.25 mm	0.3 mm

Check the wear of the synchronization ring of the 1st, 2nd and 3rd gear –  Press synchro-ring, outer ring and inner ring onto cone of synchromeshed gear and measure gap -a- using a feeler gauge.

Dimension -a-	Installation depth	Wear limit
1., 2. 3rd gears	1.2 ... 1.8 mm	0.5 mm

Installation position of the outer, inner and synchromesh rings for 2nd gear –  Fit the interior ring -A- onto the mobile pinion for 2nd gear l  The slanted projections -arrows 1- should face the outer ring -B- –  Fit over the outer ring -B-. l  The tabs -arrows 2- insert into the recesses -arrows 3- of the mobile pinion. –  Fit over the synchroniser ring -C-. l  The recesses -arrows 4- insert onto the protrusions -arrows 1- of the inner ring-A-

Disassemble and assemble the mobile element/synchroniser body for the 1st and 2nd or 3rd and 4th gear –  To disassemble, the springs must be removed -1-. 2  -  Locking piece 3  -  Mobile element 4  -  Synchro-hub –  To assemble, fit the mobile element onto the synchroniser body. l  Fitting position: The smaller rebates on the synchroniser body must coincide with the depressions of the mobile element

Assemble the mobile element / synchroniser body for the 1st and 2nd or 3rd and 4th gear l  The mobile element is fitted onto the synchroniser body –  Insert locking pieces and install springs offset 120°. l  The protruding end of the spring should enter into the locking element allotment

Installation position of locking collar with synchro-hub for 1st and 2nd gears l  The identification groove -arrow 1- and the thin collar -arrow 2- of the synchroniser body should point to the 1st gear.

Locking collar / synchronising hub for 1st and 2nd gears –  Then fit the securing ring. –  Fit the synchro-ring for 1st gear

Installation position of outer ring for 1st gear l  The tabs -arrows- must point towards the mobile element/synchroniser body -A-

Installation position of synchro-ring -A- (1st gear inner ring) l  The tabs -arrows 1- insert into the rebates -arrows 2- of the synchroniser ring -B-

Installation position for 1st gear mobile pinion The higher shoulder -A- faces towards 2nd or 4th gear -B-. The collar rebates -arrows- insert into the outer ring tabs. –  Install thrust washers for 1st and 4th gears → Item and → Item. –  Install the mobile pinion for 4th gear with the needle bearing.

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

Dimension -a-	Installation depth	Wear limit
4. gear	1.0 ... 1.7 mm	0.5 mm

Installation position of locking collar with synchro-hub for 3rd and 4th gears The widest collar of the synchroniser body -arrow- points towards the 3rd gear.

Locking collar / synchronising hub for 3rd and 4th gears –  Then fit the securing ring.

Installation position of 3rd gear outer ring l  The tabs -arrows- must point towards the mobile element/synchroniser body -A-

Installation position of synchro-ring -A- (3rd gear inner ring) l  The tabs -arrows 1- insert into the rebates -arrows 2- of the synchroniser ring -B-

Installation position for 3rd gear mobile pinion The higher shoulder -A- faces towards 2nd or 4th gear -B-. The collar rebates -arrows- insert into the outer ring tabs.   Note t  Press on tapered roller bearing inner race → Fig.. t  Determine retaining ring for tapered roller bearing inner race → Fig..