SEAT Workshop Service and Repair Manuals

Secondary shaft for 1st to 4th gear: Assemble in gearboxes manufactured from week 44/09 to 22/10

Check the inner friction surface of the 1st and 2nd gear for wear –  Press in the inner ring -A- for the cone of the pinion gear. –  Fit the outer ring -2- onto the cone of the inner ring -a- and measure the clearance gap at 3 points offset by approx. 120° using a feather key. –  Make a note of average value.

Wear limit, dimension -a-
1. st gear and 2nd gear	0.4 mm

Check the outer friction surface of the 1st and 2nd gear for wear –  Check the synchro ring -arrow- on the tyre on the inner friction surface or for an axial indication of wear, replace if necessary. –  Fit the inner ring, outer ring and the synchro-ring on the cone of the inner ring. –  Press the synchro-ring against the outer ring and turn them both to achieve the correct seating. –  Measure the clearance gap at 3 points -a- offset by approx. 120° using a feeler gauge. –  Make a note of average value.

Wear limit, dimension -a-
1. st gear and 2nd gear	0.8 mm

–  Move the mobile pinion of 2nd gear with needle bearing.

Installation of outer, inner and synchro-ring for 2nd gear –  Fit the interior ring -A- onto the mobile pinion. The lugs -1- must point in the opposite direction of the mobile pinion. –  Fit the outer ring -B-. The lugs -2- engage in the recesses -3- of the mobile pinion. –  Fit the synchroniser ring -C-. The larger recesses -4- engage in the tabs -1- of the inner rings -A-.

Disassemble and assemble the mobile element and synchroniser body for the 1st and 2nd as well as 3rd and 4th gears 1 -  Elastic ring 2 -  Locking piece 3 -  Mobile element 4 -  Synchro-hub –  Locking collar with synchronising hub installed With 3rd and 4th gear, the width of the synchroniser body collar and, if applicable, the edge reinforcement to the mobile element point in the same direction. The recesses of the synchromesh assembly and mobile element must lie over another for the locking elements.

Assemble the mobile element and synchroniser body for the 1st and 2nd as well as 3rd and 4th gears The mobile element is on the synchromesh body. –  Insert locking pieces and install springs offset 120°. The right angled end of each spring should hook on the inner hollow section of the locking part.

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

Drive the mobile element and synchromesh body into the 1st and 2nd gear The lugs -A- of the synchro-rings engage in the recesses -B- of the synchroniser body. –  Install retaining ring.

Installation of the synchro-ring, outer ring and inner ring for 1st gear –  Fit the synchroniser ring -B- to the synchroniser body. The lugs -1- engage in the recesses -2- of the synchroniser body. –  Position the outer ring -B- on the synchro-ring. The lugs -3- must point in the opposite direction of the synchro-ring. –  Mount the inner ring -C- on the outer ring. The tags -4- engage in the larger recesses -5- of the synchro-rings -A-.

Move the mobile pinion of 1st gear with needle bearing. l  The lugs -arrow A- of synchro-ring -1- are located in the recesses of the synchroniser body -2-. The tabs -arrows B- of the outer rings engage in the recesses -arrows C- of the mobile pinion -3-. –  Install thrust washers for 1st and 4th gears → Item and → Item. –  Move the mobile pinion of 4th gear with 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 dimension	Wear limit
4. gear	1.0 ... 1.7 mm	0.5 mm

Installation position for mobile element and 3rd and 4th gear synchromesh body The wider shoulder of the synchronising hub -arrow- must face towards 3rd gear.

Drive in the mobile element / synchro-hub for 3rd and 4th gear –  Turn synchro-ring so that grooves align with locking pieces. –  Install retaining ring.

Checking 3rd gear inner ring for wear –  Press inner ring onto tapered seat on selector gear and measure gap -a- using a feeler gauge.

Dimension -a-	Installation dimension	Wear limit
3. gear	0.75 ... 1.25 mm	0.3 mm

Check 3rd gear synchroniser ring for wear. –  Press synchro-ring, outer ring and inner ring against tapered seat on selector gear and measure gap -a- using a feeler gauge.

Dimension -a-	Installation dimension	Wear limit
3. gear	1.2 ... 1.8 mm	0.5 mm

–  Fit the 3rd gear synchro-ring onto the mobile sleeve and assembly and synchroniser body for 3rd and 4th gears.

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

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

Installation position for 3rd gear mobile pinion The highest collar -A- must point towards the 4th gear -B-. Notches in shoulder -arrows- engage in lugs of outer ring → Fig.. –  Move the mobile pinion of 3rd 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..