SEAT Workshop Service and Repair Manuals

Dismantling and assembling output shaft

Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Base -A-81124-, see equivalent → Anchor

t	Kit (case) -T20022-, see equivalent → Anchor

t	Extractor kit -T20140-, see equivalent → Anchor

t	Extractor kit -U 40100B-, see equivalent → Anchor

t	Kit (case) -U 40200A-, see equivalent → Anchor

t	Kit (case) -U 40300-, see equivalent → Anchor

Remove the outer track of the small roller bearing . –  On the adapter -T20140/32- fit the adapter -T20140/20- using their securing bolts. –  Fit tool assembly on lower part of outer track of roller bearing. –  Place adapter -T20140/1- on clutch casing and screw extractor shaft into adapter -T20140/20- until claws expand. –  Work nut -1- until outer track of small roller bearing is extracted.   Note Release the claws and then expand again after the outer ring has been pulled out by approx.1 mm so that it sits completely on the base of the outer ring.

Install the outer track of the small roller bearing

Removing the small roller bearing –  Put the layshaft in a vice with protected jaws -A-, so that the 4th gear mesh is facing the vice screw. –  Place the adapter -T20022/48- under the bearing rollers, then turn the bearing and tighten the fixing device again.

Install the small roller bearing –  Install flat base -U 40100/3- below the 4th gear mesh, and position adapter -U-40200/19- side A oriented towards roller bearing.

Remove bush for needle bearing, the 4th gear mesh, synchromesh unit of 3rd and 4th gear, 3rd gear mesh and 2nd gear mesh from layshaft. –  Install the adapter -U-40100/3- below the mobile pinion of the 2nd gear, and position the adapter -U-40300/2- as shown in the drawing.

Remove bush for gear needle roller bearing, synchromesh unit for 1st and 2nd gear and 1st gear mesh from layshaft. –  Remove the safety ring with pliers -A-81124-.

Pulling off large tapered roller bearing inner race   Note Before fitting puller, insert a M 10 x 20 hexagon bolt in the output shaft drilling.

Pressing on large tapered roller bearing inner race installation position –  Fit thrust washer before pressing on inner race. Shoulder faces towards inner race. –  The roller bearing side with the smaller diameter must face adapter -U-40200/18-.

Installation position of inner ring, outer ring and synchro-ring for 1st gear –  Place inner ring -A- on 1st speed selector gear. The slanted reinforcements -arrows 1- should face the outer ring -B-. –  Fit the outer ring -B-.   Note Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed gear. –  Fit the synchroniser ring -C-.   Note t  Notches -arrow 4- engage in lugs -arrow 1- of inner ring -A-. t  If components are not being renewed, make sure they are re-installed on the same gear.

Checking inner ring for 1st and 2nd gear for wear –  Before checking for wear, thoroughly clean the synchromesh rings and their corresponding gears. –  Place synchromesh ring on the corresponding gear cone. Press the synchronizer ring on the pinion and measure the dimension „a“ with a gauge.

Gap -a-	Installation dimension	Wear limit
1. and 2nd gear	0.75...1.25 mm	0.3 mm

Check 1st and 2nd gear exterior synchromesh ring for wear –  Before checking for wear, thoroughly clean the synchromesh rings and their corresponding gears. –  Place synchromesh ring on the corresponding pinion cone. Press the synchronizer ring on the pinion and measure the dimension „a“ with a gauge.

Synchro-ring	Measurement „a“ in new synchro	Wear limit
1. and 2nd gear	1.2 ... 1.8 mm	0.5 mm

Disassembly and assembly of the mobile element / synchroniser body unit for 1st and 2nd gear 1 -  Spring Allocate spring using → Electronic parts catalogue (ETKA). Installation with hollow locking pieces → Fig. Assembling version used together with solid locking pieces (no internal recess) → Fig. 2 -  Mobile element 3 -  Synchro-hub 4 -  Locking piece Allocate locking pieces using → Electronic parts catalogue (ETKA).   Note Shoulders on synchronising hub are of equal width on both sides. –  To remove the synchromesh assembly of the 1st and 2nd gear, remove the springs -1- and move the sliding sleeve -2- completely upwards. Fit the synchromesh assembly of 1st and 2nd gear in the following way: –  Place the mobile sleeve -3- on the synchromesh hub -4-, so that the grooves for the locking pins -2- on both components coincide. Installation position of the mobile element and synchromesh body When assembled, the chamfer on the shoulder of the synchronising hub and the external teeth on the locking collar -arrow A- face in the same direction. The recesses for the locking pieces on synchronising hub and locking collar -arrow C- must align.

Assembling locking collar/synchronising hub for 1st and 2nd gear (version with hollow locking pieces) l  The sliding sleeve must be fitted onto the synchromesh hub. –  Fit locking elements and install springs separated 120°. The angled ends of the springs must be inside the locking keys.

Assembling locking collar/synchronising hub for 1st and 2nd gear (version with solid locking pieces: no internal recess) l  The mobile element is on the synchromesh body. –  Insert the locking elements and install flexible rings offset by 120º. Springs must seat with angled ends in front of locking pieces -arrows-.

Installation position of the synchromesh unit of 1st and 2nd gear on the secondary shaft –  The teeth -arrow 1- of the sliding sleeve must be orientated towards the cogs -A- for seating the synchromesh assembly of the 3rd and 4th gear. –  The collar -2- of the synchromesh hub must be orientated towards the mesh -B- of 1st gear.

Install the synchromesh assembly of the 1st and 2nd gear on the secondary shaft –  Fit the 1st gear synchromesh ring on the 1st gear mesh. –  Place adapter -U-40100/3- with adapter -U-40200/19- with side A orientated towards roller bearing. –  Turn synchromesh gear so that the cut-outs coincide with the locking keys. –  After installing the synchromesh unit, fit the safety ring using pliers -A-81124-.

Identification of the rings for the 1st and 2nd gear –  1st and 2nd gear synchromesh 3 recesses -arrows-.

Installation position of middle synchromesh ring for 2nd gear –  The projections -arrows- must be orientated towards the 1st gear mesh -A-.

Installation position of inner synchromesh ring for 2nd gear –  The projections -arrows 1- of the 2nd gear interior synchromesh ring -A- must fit into the grooves -arrows 2- of the synchromesh ring -B-.

Installation position of 2nd gear pinion –  The collar -A- of the pinion of 2nd gear must be orientated towards the pinion -B- of 1st gear. –  The recesses -arrows- of the pinion of 2nd gear -A- must fit into the projections of the middle synchromesh ring.

Adapt the sleeve for 3rd gear needle bearing –  Install the gear needle roller bearing for the 2nd gear mesh and the thrust washer. –  Place adapter -U-40100/3- and adapter -U-40200/19- with side A orientated towards roller bearing. –  Place the adapter -U-40300/8- with side B orientated towards the bush and the adapter -U-40300/9- between the pressure plate and the adapter -U-40300/8-.

Check wear on synchromesh rings of 3rd and 4th gears –  Before checking for wear, thoroughly clean the synchromesh rings and their corresponding gears. –  Place synchromesh ring on the corresponding pinion cone. Press the synchromesh ring on the gear, and measure the clearance „a“ with a feeler gauge.

Synchro-ring	Measurement „a“ in new synchro	Wear limit
3. gear	1.0 ... 1.7 mm	0.5 mm
4. gear

Disassembling and assembling the synchromesh unit of 3rd and 4th gears 1 -  Spring Allocate spring using → Electronic parts catalogue (ETKA). Installation with hollow locking pieces → Fig. Assembling version used together with solid locking pieces (no internal recess) → Fig. 2 -  Locking piece Allocate locking pieces using → Electronic parts catalogue (ETKA). 3 -  Mobile element 4 -  Synchro-hub –  To remove the synchromesh assembly of the 3rd and 4th gear, remove the springs -1- and move the sliding sleeve -3- completely upwards. Mount the 3rd and 4th gear synchromesh unit as follows: –  Place the mobile sleeve -3- on the synchromesh hub -4-, so that the grooves for the locking pins -2- on both components coincide.

Assembling locking collar/synchronising hub for 3rd and 4th gear (version with hollow locking pieces) –  The sliding sleeve must be fitted onto the synchromesh hub. –  Fit locking elements and install springs separated 120°. The angled ends of the springs must be inside the locking keys.

Assembling locking collar/synchronising hub for 3rd and 4th gear (version with solid locking pieces: no internal recess) l  The mobile element is on the synchromesh body. –  Insert the locking elements and install flexible rings offset by 120º. Springs must seat with angled ends in front of locking pieces -arrows-.

Installation position of the synchromesh unit of 3rd and 4th gear –  The bevelled edge collar -arrow- on the synchromesh hub must face the 4th gear mesh.

Mount the synchromesh assembly of 3rd and 4th gear on secondary shaft –  Place the base plate -U 40100/3- with the adaptor -U-40200/19- with side -A- facing conical roller bearing. –  Turn synchromesh gear so that the cut-outs coincide with the locking keys.

Identification of synchromesh rings for 3rd and 4th gear –  3rd and 4th gear synchro ring: 3 teeth are needed -arrow-.

Install the needle bearing for 4th gear –  Place adapter -U-40100/3- and adapter -U-40200/19- with side A orientated towards roller bearing. –  Place the adaptor -U-40300/8- with side -B- orientated towards the sleeve, and the adaptor -U-40300/9- between the pressure plate and the adaptor -U-40300/8-.

Install the needle bearing for the secondary shaft –  Fit attack washer before installing bush for gear needle roller bearing. –  Remove adapter -U-40300/3- with adapter -U-40200/19- with side A orientated towards roller bearing. –  Locate adapter -U-40300/8- with side A facing the bush.