SEAT Workshop Service and Repair Manuals

Assembling output shaft 1 Overview: Gearbox disassembly → Chapter. Dismantling gearbox → Chapter. Assembling gearbox → Chapter. Dismantling and assembling clutch housing → Chapter. Dismantling and assembling outer input shaft → Chapter. Dismantling and assembling inner input shaft → Chapter. Dismantling and assembling output shaft 1 - overview → Chapter. Dismantling and assembling output shaft 2 - overview → Chapter. Dismantling and assembling output shaft 3 - overview → Chapter. Notes on gearbox adjustment → Chapter. Calculating shims for clutch housing → Chapter. Calculating shims for gearbox housing → Chapter. Gearbox identification → Chapter. Code, engine allocation → Chapter.

Special tools and workshop equipment required

t	Spanner -T10061-

t	pressure tool -VW 416B-

t	Thrust pad -VW 447I-

t	pressure tool -VW 454-

t	Installing sleeve -VW 455-

During this procedure, you can see how output shaft 1 is assembled. During the following work that is performed in the press, make sure that the shaft bearing is not damaged. If bearing is not going to be renewed then it must be protected.

l  If bearing is pressed on, thrust plate -VW 447 i- must also be used for each pressing operation. l  Pressing off bearing: → Anchor l  Pressing on bearing: → Anchor

–  Place needle bearing onto output shaft. –  Make sure that cage is not broken. –  Wet bearing with oil.

–  Place mobile pinion of 2nd gear onto the needle cage. –  Wet friction surfaces with oil. –  Place both synchro-rings with outer ring on gear wheel for 2nd gear. –  Put on locking collar with synchro-hub. Make sure groove for selector fork is pointing »upwards«, and collar of locking collar »downwards«. Synchro-hub can only be put in place. It is pressed on in next step.

–  Press on synchro-hub. Use the press tool -VW 416B-, the installing sleeve -VW 455- and the press tool -VW 454- for this purpose.   Note t  When pressing, two things must be observed: t  Raise gear wheel and turn it at same time. This allows synchro-ring to locate its installation position before ring is clamped by synchro-hub. t  Once ring has located its seat, pay attention to force required for pressing. Stop pressing as soon as you feel a stop (increased force requirement). Synchromeshed gear for 2nd gear must have axial play. Gear has reached its installation position as soon as force during pressing rises. If you continue pressing then you will be pressing synchro-hub against needle bearing, thus damaging it. After pressing, gear wheel must turn »freely« when shaft is in horizontal position.

–  Press on sleeve for needle bearing of synchromeshed gear for 4th gear. Use the press tool -VW 416B- and the press tool -VW 454- for this purpose. Installation direction: The lettering must show »downwards«.   Note Here too, stop pressing immediately when you notice a rise in force during pressing. Do not continue pressing!

–  Fit needle bearing. –  Wet bearing with oil. –  Wet friction surfaces with oil. –  Put on large synchro-ring, outer ring and small synchro-ring.

–  Put on synchromeshed gear for 4th gear.

–  Press on washer. Use the press tool -VW 416B-, the installing sleeve -VW 455- and the press tool -VW 454- for this purpose.   Note t  Here too, stop pressing immediately when you notice a rise in force during pressing. Do not continue pressing! t  After pressing, gear wheel must turn »freely« when shaft is in horizontal position. t  Output shaft is assembled as far as this washer for purpose of adjusting shaft.

Do not assemble output shaft further until gearbox has been adjusted.

–  Press on sleeve for needle bearing of synchromeshed gear for 3rd gear. Use the press tool -VW 416B- and the installing sleeve -VW 455- for this purpose.   Note Here too, stop pressing immediately when sleeve has located its position and you notice a rise in force during pressing. Do not continue pressing!

–  Fit needle bearing. –  Wet bearing and friction surfaces with oil. –  Put on synchromeshed gear for 3rd gear, small synchro-ring, outer ring and large synchro-ring.

–  Press on synchro-hub and locking collar using the press tool -VW 416B-.   Note t  When pressing, two things must be observed: t  Raise gear wheel and turn it at same time. This allows synchro-ring to locate its installation position before ring is clamped by synchro-hub. t  Once ring has located its seat, pay attention to force required for pressing. Stop pressing as soon as you feel a stop (increased force requirement). Synchromeshed gear for 3rd gear must have axial play. Gear has reached its installation position as soon as force during pressing rises. If you continue pressing then you will be pressing synchro-hub against needle bearing, thus damaging it. After pressing, gear wheel must turn »freely« when shaft is in horizontal position.

–  Press on the sleeve for needle bearing of synchromeshed gear for 1st gear using the press tool -VW 416B-.   Note Here too, stop pressing immediately when sleeve has located its position and you notice a rise in force during pressing. Do not continue pressing!

–  Fit needle bearing. –  Wet bearing and friction surfaces with oil. –  First place small synchro-ring onto synchromeshed gear for 1st gear. –  Then outer ring and then large synchro-ring. Gear wheel and rings can be placed on shaft together.

–  Press in the dished washer using the press tool -VW 416B-.   Note Here too, stop pressing immediately when washer has located its position and you notice a rise in force during pressing. Do not continue pressing! After pressing, gear wheel must turn »freely« when shaft is in horizontal position.

–  Press in the dished washer using the press tool -VW 416B-.   Note Here too, stop pressing immediately when bearing has located its position and you notice a rise in force during pressing. Do not continue pressing! –  Wet bearing with oil.

–  Tighten new bolt. Tightening torque: 60 Nm, 90° further. Special wrench -T10035- can also be used for tightening.