SEAT Workshop Service and Repair Manuals

Secondary shaft for 5th/6th and reverse gear: disassembly and assembly

Consult the equivalence table for tools and equipment according to applicability among 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	Hose clamp -T20141 -, see equivalent → Anchor

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

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

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

Extract the outer ring of roller bearing socket   Note After pulling out, check shim for damage and renew if necessary. Extraction of the outer roller bearing rings and the bearing bushes using the kit -T20140 -

Pressing tapered roller bearing outer race into clutch housing –  Fit washer under outer race.

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

Drive out the synchroniser body / mobile element for the 5th and 6th gear along with the 6th gear mobile pinion –  Remove the securing ring before releasing. –  The tool, 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 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 synchro-ring onto cone of synchromeshed gear and measure gap -a- using feeler gauge.

Installation dimension	Wear limit
1.0 ... 1.7 mm	0.5 mm

Disassembling and assembling the mobile element and synchromesh unit of 5th and 6th gears –  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 -arrow A- in the synchroniser body must coincide with the rebates -arrow B- of the mobile element

Assemble the mobile element / synchroniser body for 5th and 6th gears 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

Drive in the mobile element / synchro-hub for 5th and 6th gear –  Then fit the securing ring.

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

Determining the correct thickness securing ring –  „Determine the retaining ring with the greatest thickness “as precisely as possible → , see replacement part number replacement part catalogue, and install. Circlips available

Thickness (mm)
1,79	1,89	1,98
1,83	1,92
1,86	1,95

Insert the inner ring of roller bearing

Pulling outer race for tapered roller bearing out of gearbox housing

Fitting the outer ring of the roller bearing into the gearbox casing –  Place thrust piece -U-40200/14- directly under bearing mounting to support gearbox housing.