SEAT Workshop Service and Repair Manuals

Secondary shaft: dismantling and assembling

Special tools and workshop equipment required

t	Case -U-40100-

t	Case -U-40200-

t	Case -U-40300-

t	Interior extractor with striker (2 legs) -T20004-

t	Pliers for opening elastic rings -A-81124-

t	Whenever new pinions or gearbox shaft parts are fitted, it is necessary to consult the section Distinctive lettering, group correspondence, demultiplications, filling quantities → Chapter.

t	Fit all bearing, sliding pinions and synchroniser rings in the gearbox duly lubricated with gear oil.

1 -	Hexagonal nut, 60 Nm

q	Must always be replaced when removed

q	Follow the corresponding fitting sequence to loosen or tighten the hexagonal nut → Chapter

2 -	Leaf spring

q	Fitting position: the exterior diameter (concave side) faces the 5th gear

3 -	Support ring

4 -

Spring

q	Fitting position → Fig.

5 -	5th gear movable

q	Removing and refitting → Chapter

q	Fitting position → Fig.

6 -	5th gear synchroniser

q	Removing and refitting → Chapter

q	Fitting position → Fig.

7 -	Locking parts (3 units)

q	Fitting position → Fig.

8 -	5th gear synchroniser ring

q	Checking for wear → Fig.

9 -	5th gear sliding pinion

10 -	Needle bearing

11 -	Bushing for needle bearing

q	Observe the fitting position → Chapter

12 -	Gearbox housing

13 -	Ball bearing

q	Releasing → Fig.

q	Fitting → Fig.

14 -	Sliding pinion for 4th gear

15 -	Safety ring

q	Always replace when removed

q	Separate and fit with the tool -A-81124-

16 -	4th gear synchroniser ring

q	Checking for wear → Fig.

17 -

Spring

q	Fitting position → Fig.

18 -	Sliding sleeve

19 -	Synchroniser

20 -	Locking parts (3 units)

21 -	Unit comprising sliding sleeve and synchroniser for 3rd and 4th gear

q	Fitting position of the synchroniser → Fig.

q	Assembly of the movable /synchroniser body → Fig. und → Fig.

22 -	Synchroniser ring for 3rd gear

q	Checking for wear → Fig.

23 -	Sliding pinion for 3rd gear

24 -

Washer

q	Keeps the drive washers → Item in their place on the secondary shaft

25 -	Drive washer

q	For 2nd and 3rd gears

q	Fit the lips of the drive washer in the holes on the secondary shaft

26 -	Sliding pinion for 2nd gear

27 -	Synchroniser ring for 2nd gear

q	Checking for wear → Fig.

28 -	Sliding sleeve with synchroniser for 1st and 2nd gear

q	Assembly of the movable /synchroniser body → Fig. and → Fig.

29 -	Synchroniser ring for 1st gear

q	Checking for wear → Fig.

30 -	Sliding pinion for 1st gear

31 -	Secondary shaft

q	This incorporates the pinion for controlling the half-shafts; if replaced, the half-shaft control should also be changed

32 -	Cylindrical roller bearing

q	Extracting → Fig.

q	Fitting → Fig.

q	Fitting position: the identification of the bearing should face upwards, → Fig.

33 -

Sleeve

q	For the oil guide

q	Replace every time the conic roller bearing is dismantled → Item

34 -

Washer

35 -	Hexagonal bolt, 10 Nm

Remove the ball bearing together with the sliding pinion of the 4th gear Push with the tool -U-10050A- (H centring tool). Fit the tool -U-40100/4- under the pinion of the 4th gear.

Dismantling and assembling the movable and the synchroniser of the 3rd, 4th or 5th gear 1 -  Spring 2 -  Movable 3 -  Synchroniser body 4 -  Locking part –  Move the sliding sleeve over the synchroniser. The burrs for the locking parts of the synchroniser and the movable must line up.

Assembling the movable/synchroniser of the 3rd, 4th or 5th gear The sliding sleeve is on the synchroniser. Fit the locking parts and fit the springs moved by 120º. The folded end of the spring must fit in the hole of the synchroniser -arrow-.

Fitting position of the movable/synchroniser of the 3rd, 4th or 5th gear The wide collar of the synchroniser -arrow- faces the 4th gear.

Dismantling and assembling the movable and the synchroniser body of the 1st and 2nd gear 1 -  Spring 2 -  Movable 3 -  Synchroniser body 4 -  Locking part –  Move the sliding sleeve over the synchroniser body. The burrs for the locking parts of the synchroniser and the movable must line up.

Assembly of the movable/synchroniser body of 1st and 2nd gear The sliding sleeve is on the synchroniser. Fit the locking parts and fit the springs moved by 120º. The folded end of the spring must fit in the hole of the synchroniser -arrow-.

Fitting the grooved ball bearing

Extracting the cylindrical roller bearing from the clutch housing –  Open the legs of the extractor -T20004- under the cylindrical roller bearing.

Fitting the cylindrical roller bearing

Checking the synchroniser ring for wear –  Press the synchroniser ring on the cone of the sliding pinion and measure the distance -a- with a vernier calliper.

Distance “a”	Assembly dimension	Wear limit
1st - 5th gear	1.2 … 1.8 mm	0.5 mm