SEAT Workshop Service and Repair Manuals

Notes:

• ◆ When installing new gears, consult technical data
  .
• ◆ If the position of the taper roller bearings is affected when exchanging parts, the input shaft must be re-adjusted. See adjustment overview

• Gearbox housing
• Taper roller bearing outer race
• ◆ Pulling out => Fig.1
• ◆ Pressing in => Fig.2
• Taper roller bearing inner race
• ◆ Pulling off => Fig.3
• ◆ Pressing on => fig.15
• Circlip

• 5th gear wheel
• ◆ Pressing off => Fig.4
• ◆ Pressing on => Fig.14
• Selector gear for 4th gear
• ◆ Removing =>Fig.5
• Needle roller bearing
• ◆ For 4th gear
• 4th gear synchro-ring
• Circlip
• Locking collar with 3rd and 4th gear synchro-hub
• ◆ Removing =>Fig.6
• ◆ Dismantling => Fig.8
• ◆ Installation position => Fig.13
• ◆ Assembling => Fig. 12
• 3rd gear synchro-ring
• ◆ Installation position => Fig.11

• 3rd gear outer ring
• ◆ Insert in the synchro-ring (item13)
• ◆ Insert into gear wheel recess
• ◆ Installation position => Fig.11
• Synchro-ring
• ◆ (3rd gear inner ring)
• ◆ Installation position => Fig.11
• Selector gear for 3rd gear
• ◆ Removing =>Fig.7
• Needle roller bearing
• ◆ For 3rd gear
• Clutch housing
• Shim
• ◆ Determining thickness => adjusting input shaft, Page 35-14

• Taper roller bearing outer race
• ◆ Pulling out => Fig.16
• ◆ Pressing in => Fig.17
• Taper roller bearing inner race
• ◆ Pressing off => Fig.9
• ◆ Pressing on => Fig. 10
• Input shaft
• ◆ Adjusting => Page 35-14
• Locking collar
• Locking pieces (Qty. 3)
• ◆ With springs and balls
• Synchro-hub

→ Fig.1    Pulling taper roller bearing outer race out from gearbox housing

A - Counter support, e.g. Kukko 22/1

B - Internal extractor 28 ... 40 mm, e.g. Kukko 21/5

→ Fig.2    Pressing taper roller bearing outer race into gearbox housing

→ Fig.3    Pulling off taper roller bearing inner race

→ Fig.4    Pressing off 5th gear wheel

• ‒ First remove securing clip.

A - Separating device 22 ... 115 mm, e.g. Kukko 17/2

→ Fig.5    Removing 4th gear wheel

• ‒ Take off gear wheel (item1) together with needle bearing (item 2) and syncro-ring (item 3).

→ Fig.6    Removing locking collar and synchro-hub for 3rd and 4th gear

• ‒ Take off securing ring (item1).
• ‒ Pull locking collar/syncro-hub (item 2) off by hand.

→ Fig.7    Removing 3rd gear wheel

• ‒ Take off gear wheel (item 4) together with syncro-ring (item1), outer ring (item 2) and inner ring (item 3).
• ‒ Take off needle bearing (item 5).

→ Fig.8    Dismantling locking collar and synchro-hub for 3rd and 4th gear

•     1 -    Locking collar
•     2 -    Syncro-hub
•     3 -    Spring (Qty. 3)
•     4 -    Locking piece (Qty. 3)
•     5 -    Locking ball (Qty. 3)

→ Fig.9    Pressing off taper roller bearing inner race

A - Separating device 22 ... 115 mm, e.g. Kukko 17/2

→ Fig.10    Pressing on taper roller bearing inner race

→ Fig.11    Installation position of outer ring, inner ring and 3rd gear synchro-ring

• ‒ Place inner ring -A- on gear wheel.
• ‒ Fit outer ring -B-.

The lugs (arrow 1) engage in the gear wheel recesses (arrow 2).

• ‒ Fit synchro-ring -C-.

The lugs (arrow 3) engage in the inner ring -A- recesses (arrow 4).

→ Fig.12    Assembling locking collar and synchro-hub for 3rd and 4th gear

• ‒ Insert springs (item 3).
• ‒ Insert locking pieces (item 4) with locking ball (item 5) in syncro-hub (item 2) against spring pressure.
• ‒ Correctly position (arrows) locking collar (item1) and slide on.

→ Fig.13    Installation position of 3rd and 4th gear locking collar/synchro-hub

The wider shoulder of the synchro-hub (arrow) faces towards 4th gear.

→ Fig.14    Pressing on 5th gear wheel

→ Fig.15    Pressing on taper roller bearing inner race

→ Fig.16    Pulling taper roller bearing outer race out from clutch housing

A - Counter support, e.g. Kukko 22/2

B - Internal puller 36...46 mm, e.g. Kukko 21/6

→ Fig.17    Pressing taper roller bearing outer race into clutch housing