SEAT Workshop Service and Repair Manuals

Input shaft: dismantling and assembling

Special tools and workshop equipment required

t	Gearbox extractor set -U-40100-

t	Gearbox repair set -U-40200-

t	Tool for removing/fitting stop ring 5th gear -T20085-

Whenever new gears are fitted consult the technical data, → Chapter, Code letters, group numbers, ratios, filling quantities

1 -

Bolt

q

150 Nm

q

Renew

q	Removing and fitting → Chapter

2 -	Plate spring

3 -	Syncromesh assembly 5th gear

q	Removing and fitting → Chapter, Assembly sequence

4 -

Stop ring

q	Stops the locking keys from being released

q	Remove → Fig.

q	Fit → Fig.

5 -

Spring

6 -	Sliding sleeve for 5th gear

q	Installation position → Fig.

7 -	Syncromesh hub 5th gear

8 -	Locking keyways

q

3 units

9 -	Countersunk bolt

q

15Nm

q

M7 x 23

q

4 units

10 -	Ball bearing

q	Remove → Fig.

q	Fit → Fig.

11 -	Fixing plate

q	Secures the ball bearing

12 -	Sliding 4th gear

13 -	Syncromesh ring for 4th gear

q	Checking for wear → Fig.

14 -	Safety ring

q

Renew

15 -	3rd and 4th syncromesh assembly

q	Remove together with 3rd gear → Fig.

q	Syncromesh installation position , → Fig.

q	Assemble → Fig.

q	Fit → Fig.

16 -	Sliding sleeve

17 -	Syncromesh hub

18 -	Locking keyways

q

3 units

19 -

Spring

20 -	Clutch housing

21 -	Clutch housing

22 -	Needle roller bearing

q	For input shaft

q	Removing and fitting → Chapter, Assembly sequence

23 -	Oilseal for clutch pushrod

q	Can be replaced with the geabox removed (not dismantled)

q	Remove by levering with a screwdriver → Fig.

q	Installation position → Fig.

q	Fit → Fig.

24 -	Bush for clutch pushrod

q	Can be replaced with the geabox removed (not dismantled)

q	Remove → Fig.

q	Installation position → Fig.

q	Fit → Fig.

25 -	Sliding 3rd gear

26 -	Syncromesh ring 3rd gear

q	Checking for wear → Fig.

27 -	Gearbox casing

28 -

Shim

q	For input shaft

q	See → Item

29 -	Thrust washer

q	Installation position → Fig.

q	Once the 5th gear syncromesh ring has been fitted, → Item, fit the sliding 5th gear, → Item, on the syncromesh hub → Item

30 -	Sliding 5th gear

31 -	Syncromesh ring 5th gear

q	Checking for wear → Fig.

Remove by levering the clutch pushrod oilseal

Assembly position of oilseal and bush A -  Oilseal for clutch pushrod B -  Bush for clutch pushrod

Fit the clutch pushrod oilseal –  Fitting the oilseal -A- together with the cap -B- supplied, so that it is flush. Remove assembly cap -B-: the depth of oilseal fitting is now 0.8 ... 1.3 mm. Lubricate the oilseal lip lightly.

Remove by levering the clutch pushrod oilseal –  Screw tool -U-40200/22- into the bush and action the hammer extractor -U-40200/21- to remove the bush.

Fit the clutch pushrod bush home

Removing the roller bearing –  After separate the tensioning plate, the sliding 4th gear and the needle roller bearing. –  Remove the syncromesh ring and the circlip that secures the syncromesh hub for 3rd and 4th gear.

Remove the 3rd and 4th gear syncromesh assembly with the 3rd gear

Checking syncromesh ring wear –  Press the syncromesh ring onto the cone of the sliding gear and measure dimension “a” with a feeler gauge.

Syncromesh ring	Measurement “a” on a new syncromesh	Wear limit
3rd gear 4th gear 5th gear	1.15 ... 1.75 mm 1.3 ... 1.9 mm 1.3 ... 1.9 mm	0.5 mm

Assembly position for syncromesh hub, 3rd and 4th gears The shorter teeth under the groove -arrow A- face the 3rd gear. The front groove -arrow B- faces the 4th gear.

Assembly of sliding sleeve for 3rd and 4th gear syncromesh hub –  Slide the sleeve onto the syncromesh hub. The recesses for the syncromesh locking keys and the sleeve must line up. –  Insert the locking keys and fit the springs at 120 ° from each other. The angled ends of the springs must locate in the inner hollow of the corresponding locking keys.

Fitting the syncromesh assembly for 3rd and 4th gears

Removing the roller bearing

Assembly position for 5th gear sliding sleeve –  Slide the sleeve onto the syncromesh hub. The recesses for the syncromesh locking keys and the sleeve must line up. The bevel on the teeth -arrow 1- faces the 5th gear syncromesh hub shaft -arrow 2-. –  Insert the locking keys and fit the springs at 120 ° from each other. The angled ends of the springs must locate in the inner hollow of the corresponding locking keys.

Assembly position of the 5th gear thrust washer The bevel -arrow- should be opposite the gear.

Remove the stop circlip –  Place tool -T20085- inside the syncromesh ring/stop assembly and remove the stop circlip.

Fit the stop circlip –  Insert tool -T20085- inside the stop circlip and locate the clip inside the syncromesh ring. –  The stop ring tabs should be anchored in the recesses of the syncromesh ring locking keys -arrows-.