SEAT Workshop Service and Repair Manuals

5th/6th gear: Install

Installation position of 5th gear pinion: The lobe present -arrow- on the internal diameter of the gear must be orientated towards the gearbox casing. –  Heat heat the pinion gear for 5th gear to approx. 100 ºC with the hot air blower -SAT 1416-.

Installing the gear pinion for 5th gear

5th and 6th gear synchro ring: Check for wear –  Before reassembling the gears and the synchromesh rings for the 5th and 6th gear, the synchromesh rings must be fitted into the mobile pinion cone. Measure the distance -a- with a feeler gauge.

Dimension -a-	Installation dimension	Wear limit
5./ 6. gear	1,1. .. 1.7 mm	0.5 mm

–  Insert the mobile pinion of the 5th gear with the needle bearing –  Fit 5th gear synchro ring on the mobile pinion. With gearboxes manufactured from week 22/2008, fit a corrugated spring washer on the selector gear for 5th gear → Chapter. –  Fit 5th gear synchro ring on the mobile pinion. –  If this is disassembled, assemble the mobile element and the synchromesh for the 5th / 6th gear before fitting → Fig., → Fig. and → Fig.. –  With gearboxes manufactured from week 24/2006,the modification of the selector gear for 5th / 6th gear must be observed → Fig.. These modifications are very important for the later adjustment of the 5th and 6th gears.

Installation position for mobile and 5th / 6th gear synchromesh The reinforcement -arrow 1- faces towards the 6th gear. The allotments -arrow 2- of the synchromesh are located at the same level as the locking elements (cast iron) of the synchroniser ring.

5th and 6th gear synchro ring with locking elements -arrows- –  To prevent dirt from entering the gearbox, cover all the holes with a lint-free cloth.

Insert the synchromesh assembly for 5th / 6th gear.   Note t  When fitting it, ensure that the synchromesh ring fits into its respective space. t  Do not change the position of used synchromesh rings during reassembly.

–  Heat the mobile pinion roller bearing socket inner ring for the 6th gear to approx. 100 °C using the hot air blower -SAT 1416-, and fit it into the input shaft.   WARNING Wear protective gloves! –  Fit the synchro-ring for 6th gear With gearboxes manufactured from week 22/2008, fit a corrugated spring washer on the selector gear for 6th gear → Item. –  Fit 6th gear selector gear with the needle bearing. For gearboxes manufactured up to week 34/2006

–  Fit the thrust ring -A- on top.   Note Do not confuse the inner rings / roller bearings of the input shaft and those of the secondary shaft. –  Heat the roller bearing socket inner ring -B- to approx. 100 ºC with the hot air blower -SAT 1416-, and fit it onto the input shaft.   WARNING Wear protective gloves!

With gearboxes manufactured from week 34/2006 Conical roller bearing inner race -B- and thrust washer -A- are combined to one component. –  Heat the roller bearing inner race to maximum 100 ºC, and fit it onto the input shaft.   WARNING Wear protective gloves! Continued for all vehicles

–  Before installing the pinion gear of the 6th gear, fit the spacer sleeves -A- for fixing the pinion gears of 5th and 6th gears. –  Heat heat the pinion gear for 6th gear to approx. 100 ºC with the hot air blower -SAT 1416-.   WARNING Wear protective gloves!

Installation position of 6th gear pinion:

Groove -B- faces away from sleeve -A-. »Or« groove -arrow 1- near the groove area -arrow 2- must face away from sleeve -A- (see also previous figure). –  Position the mobile sleeve -A- for 5th / 6th gear in neutral position so that the mobile pinion for 6th gear does not rotate when the 6th gear pinion is installed. –  Insert the 6th gear pinion and ensure, when doing so, that the cogs of the 6th gear pinion -B- and the 6th gear mobile pinion engage correctly. –  Heat the roller bearing socket inner ring -A- to approx. 100 °C with the hot air blower -SAT 1416-, and insert it onto the secondary shaft.   WARNING Wear protective gloves! –  Screw in the fixing bolts onto the synchromesh element and the gear pinion for 5th / 6th gear.

–  Two gears must be engaged -arrows 1 and 3- before the securing bolts can be tightened -A-. The allocation of fixing screws → Fig. and → Fig. must be considered. –  Fasten bolts-A- and tighten to the respective tightening torque → Chapter. –  Install 5th / 6th gear connection prong.

Synchronisation of 5th / 6th gears for gearboxes manufactured up to week 24/2006 –  Select 5th gear. –  Loosen bolt -1-. –  Insert two feeler gauges -A- of 0.5 mm above the two detent segments -arrows- (for 6th gear) into locking collar. –  Press down selector jaw and locking collar -arrows- and tighten bolt -1- to 25 Nm. l  The 5th gear is engaged.

l  Control measurement: it should be possible to insert a 0.5 mm feeler gauge without play between locking collar and each selector segment -arrow- on the side of 6th gear. –  If necessary, repeat the adjustment process. –  Engage 5th gear and then 6th gear. There must be slight play between 5th/6th gear selector fork and selector jaw with 5th or 6th gear engaged. –  Disengage gear. l  Locking collar should now be in the neutral position. Synchro-ring must move freely. –  Successively select all gears several times.

Synchronisation of 5th / 6th gears for gearboxes manufactured from week 24/2006 –  Select 5th gear. –  Loosen bolt -1-. –  Press down selector jaw and locking collar -arrows- and tighten bolt -1- to 25 Nm. l  The 5th gear is engaged.

l  Control measurement: it should be possible to insert a 0.2 mm feeler gauge without play between locking collar and each selector segment -arrow- on the side of 6th gear. –  If necessary, repeat the adjustment process. –  Engage 5th gear and then 6th gear. There must be slight play between 5th/6th gear selector fork and selector jaw with 5th or 6th gear engaged. –  Disengage gear. l  Locking collar should now be in the neutral position. Synchro-ring must move freely. Continued for all vehicles –  Successively select all gears several times. –  Fit the gearbox casing cover → Item. –  Install the guide sleeve for the clutch release bearing. –  Fit the clutch release lever and clutch release bearing.