SEAT Workshop Service and Repair Manuals

Notes:

• ◆ When installing new gears or a new output shaft consult technical data
  .
• ◆ The output shaft must be re-adjusted, if the position of the taper roller bearings is affected when exchanging parts. See adjustment overview
• ◆ Removing and installing output shaft
  => Page 34-95.
• ◆ Both taper roller bearings must be renewed together as a set.

• Gearbox housing
• Taper roller bearing outer race
• ◆ Removing => Fig.1
• ◆ Pressing in => Fig.2
• Taper roller bearing inner race
• ◆ Press off with reverse gear wheel
  => Fig.3
• ◆ Pressing on => Fig.20
• Reverse sliding gear wheel
• ◆ Removing => Fig.4
• Needle roller bearing
• ◆ For reverse gear wheel
• Reverse gear synchro-ring
• Securing clip

• 5th and reverse gear locking collar with synchro-hub
• ◆ Removing =>Fig.5
• ◆ Dismantling => Fig.13
• ◆ Assembling => Fig.15
• ◆ Installation position => Fig.19
• 5th gear synchro-ring
• Selector gear for 5th gear
• ◆ Removing =>Fig.6
• Needle roller bearing
• ◆ For 5th gear
• Securing clip
• 4th gear
• ◆ Collar faces to 3rd gear
• ◆ Pressing off=> Fig.7
• ◆ Pressing on => Fig.18

• 3rd gear
• ◆ Shoulder points to 4th gear
• ◆ Pressing off => Fig.8
• ◆ Pressing on => Fig.17
• Locking collar
• Locking pieces (Qty. 3)
• ◆ With spring and ball
• Synchro-hub
• Needle roller bearing
• ◆ For 2nd gear
• 2nd gear wheel
• ◆ Removing =>Fig.9
• Synchro-ring
• ◆ (2nd gear inner ring)
• ◆ Installation position => Fig.14
• 2nd gear outer ring
• ◆ Place on synchro-ring (item 20)
• ◆ Insert in gear wheel recess
• ◆ Installation position => Fig.14

• 2nd gear synchro-ring
• ◆ Installation position => Fig.14
• Securing clip
• 1st and 2nd gear locking collar with synchro-hub
• ◆ Removing =>Fig.10
• ◆ Dismantling => Fig.13
• ◆ Assembling => Fig.15
• ◆ Installation position => Fig.16
• 1st gear synchro-ring
• ◆ Installation position => Fig.14
• 1st gear outer ring
• ◆ Place on synchro-ring (item27)
• ◆ Insert in gear wheel recess
• ◆ Installation position => Fig.14
• Synchro-ring
• ◆ (1st gear inner ring)
• ◆ Installation position => Fig.14

• 1st selector gear
• ◆ Removing =>Fig.11
• Needle roller bearing
• ◆ For 1st gear
• Output shaft
• ◆ Is paired with final drive gear, always renew together as a set
• ◆ Adjusting => Page 35-38
• Taper roller bearing inner race
• ◆ Pressing off => Fig.4
• ◆ Pressing on => Fig.21
• Taper roller bearing outer race
• ◆ Removing => Fig.22
• ◆ Pressing in => Fig.23
• Shim
• ◆ Determining thickness - adjusting output shaft => Page 35-38
• Clutch housing

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

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

B - Internal puller 46...58 mm, e.g. Kukko 21/7

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

→ Fig.3    Pressing off taper roller bearing inner race

• ‒ Press off taper roller inner race via reverse gear wheel.

→ Fig.4    Removing reverse gear wheel

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

→ Fig.5    Removing 5th and reverse gear locking collar and synchro-hub

• ‒ After removing securing ring (item1) take off locking collar/synchro-hub (item 2).

→ Fig.6    Removing 5th gear wheel

• ‒ Take off synchro-ring (item1) together with 5th gear wheel (item 2) and needle bearing (item 3).

→ Fig.7    Pressing off 4th gear wheel

• ‒ First remove securing clip.

→ Fig.8    Pressing off 3rd gear wheel

• ‒ Press off 3rd gear wheel via 2nd gear wheel.

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

Note:

Fit separating device under 2nd gear with flatter side facing upwards.

→ Fig.9    Removing 2nd gear wheel

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

→ Fig.10    Removing 1st and 2nd gear locking collar and synchro-hub

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

→ Fig.11    Removing 1st gear wheel

• ‒ Take 1st gear wheel (item 2) off together with synchro-ring (item 5), outer ring (item 4) and inner ring (item 3).
• ‒ Remove needle bearing (item1).

→ Fig.12    Pulling off taper roller bearing inner race

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

→ Fig.13    Dismantling and assembling locking collar and synchro-hub

•     1 -    Locking collar
•     2 -    Synchro-hub
•     3 -    Spring (Qty. 3)
•     4 -    Locking piece (Qty. 3)

•     5 -    Locking ball (Qty. 3)

→ Fig.14    Installation position of outer ring, inner ring and synchro-ring for 1st gear wheel and for 2nd gear wheel

• ‒ 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.15    Assembling locking collar and synchro-hub

• ‒ Insert springs (item 3).
• ‒ Insert locking piece (item 4) with locking ball (item 5) into synchro-hub (item 2) against spring pressure.
• ‒ Position locking collar (item1) correctly (arrows) and slide on.

→ Fig.16    Installation position of 1st and 2nd gear locking collar/synchro-hub

The wider shoulder of the synchro-hub (arrow) faces towards 2nd gear.

→ Fig.17    Pressing on 3rd gear wheel

Shoulder points towards 4th gear.

→ Fig.18    Pressing on 4th gear wheel

Shoulder points to 3rd gear.

• ‒ Fit securing ring.

→ Fig.19    Installation position of 5th and reverse gear locking collar/synchro-hub

The wider shoulder of the synchro-hub (arrow) faces towards 5th gear -B-.

→ Fig.20    Pressing on taper roller bearing inner race

→ Fig.21    Pressing on taper roller bearing inner race

→ Fig.22    Pulling taper roller bearing outer race out from clutch housing

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

B - Internal puller 46...58 mm, e.g. Kukko 21/7

→ Fig.23    Pressing taper roller bearing outer race into clutch housing