SEAT Workshop Service and Repair Manuals

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

Special tools and workshop equipment required

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

t	Kit (case) -T20022-, see equivalent → Anchor

t	Extractor kit -T20140-, see equivalent → Anchor

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

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

t	Kit (case) -U 40300-, see equivalent → Anchor

Remove the outer track of the conical roller bearing –  On the adapter -T20140/32- fit the adapter -T20140/20- using their securing bolts. –  Fit tool assembly on lower part of outer track of roller bearing. –  Place adapter -T20140/1- on clutch casing and screw extractor shaft into adapter -T20140/20- until claws expand. –  Work nut -1- until outer track of small roller bearing is extracted.   Note Release the claws and then expand again after the outer ring has been pulled out by approx.1 mm so that it sits completely on the base of the outer ring.

clutch housing: fit conical roller bearings

Removing the small roller bearing –  Put the layshaft in a vice with protected jaws -A-, so that the 4th gear mesh is facing the vice screw. –  Place adapter -T20022/48- under the roller bearing and tighten hard.

Install the small roller bearing –  Install the adapter -U-40100/3- below the gear of the 4th gear, and position the adaptor -U-40200/19- with side -A- orientated towards the small conical roller bearing.

Remove bush for needle bearing, the 4th gear mesh, synchromesh unit of 3rd and 4th gear, 3rd gear mesh and 2nd gear mesh from layshaft. –  Install the adapter -U-40100/3- below the mobile pinion of the 2nd gear, and position the adapter -U-40300/2- as shown in the drawing.

Remove bush for gear needle roller bearing, synchromesh unit for 1st and 2nd gear and 1st gear mesh from layshaft. –  Remove the safety ring with pliers -A-81124-.

Removing the large roller bearing

Install the large roller bearing installation position –  The roller bearing side with the smaller diameter must face adapter -U-40200/18-.

Installation position of 1st gear outer ring –  Fit the interior ring -A- onto the mobile pinion for 1st gear. The slanted reinforcements -arrows 1- should face the outer ring -B-. –  Fit the outer ring -B-. The reinforcements -arrows 2- fit into the grooves -arrow 3- of the mobile gear. –  Fit the synchroniser ring -C-. The recesses -arrows 4- insert into the reinforcements -arrows 1- of the inner ring-A-.   Note If components are not to be replaced, ensure that these are allocated to their corresponding gears.

Identification of the rings for the 1st and 2nd gear –  1st and 2nd gear synchromesh 3 recesses -arrows-.

Checking 1st and 2nd gear inner synchro-ring for wear –  Before checking for wear, thoroughly clean the synchromesh rings and their corresponding gears. –  Place synchromesh ring on the corresponding pinion cone. Press the synchromesh ring on the gear, and measure the clearance „a“ with a feeler gauge.

Synchro-ring	Measurement „a“ in new synchro	Wear limit
1st and 2nd gears	0.75...1.25 mm	0.3 mm

Checking 1st and 2nd gear outer synchro-ring for wear –  Before checking for wear, clean the syncromesh rings and their corresponding gears thoroughly. –  Place synchromesh ring on the corresponding pinion cone. Press the synchromesh ring on the gear, and measure the clearance „a“ with a feeler gauge.

Synchro-ring	Measurement „a“ in new synchro	Wear limit
1st and 2nd gears	1.2 ... 1.8 mm	0.5 mm

Disassemble and assemble the synchromesh assembly of the 1st and 2nd gear 1 -  Spring Allocate springs according to → Electronic parts catalogue „ETKA“. Installation with hollow locking pieces → Fig.. Installation with solid locking pieces → Fig.. 2 -  Mobile element 3 -  Synchro-hub 4 -  Locking piece Allocate locking pieces according to → Electronic parts catalogue „ETKA“. Shoulders on synchronising hub are of equal width on both sides. The shoulder on one side is chamfered -arrow B-. When assembled, the chamfer on the shoulder of the synchronising hub and the external teeth on the locking collar -arrow A- face in the same direction. The recesses for the locking pieces on synchronising hub and locking collar -arrow C- must align.

Assembling synchronising hub for 1st and 2nd gear in conjunction with hollow locking pieces l  The mobile element is on the synchromesh body. –  Insert locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece.

Assembling synchronising hub for 1st and 2nd gear in conjunction with locking pieces that are not hollow l  The mobile element is on the synchromesh body. –  Insert locking pieces and install springs offset 120°. Springs must seat with angled ends in front of locking pieces. -arrows-.

Installation position of the synchromesh unit of 1st and 2nd gear –  The teeth -arrow 1- of the sliding sleeve must be orientated towards the cogs -A- for seating the synchromesh assembly of the 3rd and 4th gear. –  The collar -2- of the synchromesh hub must be orientated towards the mesh -B- of 1st gear.

Install the synchromesh assembly of the 1st and 2nd gear on the secondary shaft –  Fit the 1st gear synchromesh ring on the 1st gear mesh. –  Place the adaptor -U-40100/3- with the adaptor -U-40200/19- with side -A- orientated towards the conical roller bearing. –  Turn synchromesh gear so that the cut-outs coincide with the locking keys. –  After installing the synchromesh unit, fit the safety ring using pliers -A-81124-.

Installation position of middle synchromesh ring for 3rd gear –  The projections -arrows- must be orientated towards the 1st gear mesh -A-.

Installation position of inner synchromesh ring for 2nd gear –  The projections -arrows 1- of the 2nd gear interior synchromesh ring -A- must fit into the grooves -arrows 2- of the synchromesh ring -B-.

Installation position of 2nd gear pinion –  The collar -A- of the 2nd gear mesh must be orientated towards the 1st gear mesh -B-. –  The recesses -arrows- of the pinion of 2nd gear -A- must fit into the projections of the middle synchromesh ring.

Install bush for gear needle roller bearing –  Install the gear needle roller bearing for the 2nd gear mesh and the thrust washer. –  Place the adaptor -U-40100/3- and the adaptor -U-40200/19- with side -A- orientated towards the conical roller bearing. –  Place the adaptor -U-40300/8- with side -B- orientated towards the sleeve, and the adaptor -U-40300/9- between the pressure plate and the adaptor -U-40300/8-.

Verify the wear of 3rd and 4th gear rings –  Before checking for wear, thoroughly clean the synchromesh rings and their corresponding gears. –  Place synchromesh ring on the corresponding pinion cone. Press the synchromesh ring on the gear, and measure the clearance „a“ with a feeler gauge.

Synchro-ring	Measurement „a“ in new synchro	Wear limit
1st gear
3rd gear	1.0 ... 1.7 mm	0.5 mm
4. gear

Disassembling and assembling the synchromesh unit of 3rd and 4th gears 1 -  Spring Allocate springs according to → Electronic parts catalogue „ETKA“. Installation with hollow locking pieces → Fig.. Installation with solid locking pieces → Fig.. 2 -  Locking piece Allocate locking pieces according to → Electronic parts catalogue „ETKA“. 3 -  Mobile element 4 -  Synchro-hub –  Slide locking collar over synchro-hub. The recesses of the synchromesh assembly and mobile element must lie over another for the locking elements.

Assembling synchronising hub for 3rd and 4th gear in conjunction with hollow locking pieces l  The mobile element is on the synchromesh body. –  Insert locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece.

Assembling synchronising hub for 3rd and 4th gear in conjunction with locking pieces that are not hollow l  The mobile element is on the synchromesh body. –  Insert locking pieces and install springs offset 120°. Springs must seat with angled ends in front of locking pieces -arrows-.

Installation position of the synchromesh unit of 3rd and 4th gear –  The bevelled edge collar -arrow- on the synchromesh hub must face the 4th gear mesh.

Mount the synchromesh assembly of 3rd and 4th gear on secondary shaft –  Place -U-40100/3- with adapter -U-40200/19- with side A facing roller bearing. –  Turn synchromesh gear so that the cut-outs coincide with the locking keys.

Identification of synchromesh rings for 3rd and 4th gear –  3rd and 4th gear synchro ring: 3 teeth are needed -arrow-.

Install bush for gear needle roller bearing –  Place the adaptor -U-40100/3- and the adaptor -U-40200/19- with side -A- orientated towards the conical roller bearing. –  Place the tool U-40300/8 with side-B- orientated towards the sleeve, and the adaptor -U-40300/9- between the pressure plate and the adaptor -U-40300/8-.

Install bush for gear needle roller bearing –  Fit attack washer before installing bush for gear needle roller bearing. –  Remove the adaptor -U-40300/3- with the adaptor -U-40200/19- with side -A- orientated towards the conical roller bearing. –  Place the adaptor -U-40300/8- with side -A- facing the sleeve.