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	Gearbox repair set -U-40300-

t	Circlip opening pliers -A-81124-

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

t	The input shaft must be adjusted whenever elements have been replaced which could affect the position of the roller bearings. Refer to Adjustment chart → Chapter.

1 -	Clutch housing

q	Repairing → Chapter

2 -	Outer track, roller bearing

q	Remove → Fig.

q	Fit → Fig.

3 -	Roller bearing

q	Remove → Fig.

q	Fit → Fig.

4 -	Input shaft

q	Adjusting → Chapter

5 -

3rd gear

q	Remove → Fig.

q	Fit → Fig.

q	Assembly position: the collar must be facing the 4th gear

6 -	Safety ring

q	Use tool -A-81124- to remove the circlip

q	Always renew

7 -

4th gear

q	Remove together with the roller bearings → Item, stop washer → Item and bush → Item → Fig.

q	Fit → Fig.

q	Assembly position: the collar must be facing the 3rd gear

8 -	Roller bearing

q	Remove → Fig.

q	Fit → Fig.

9 -	Stop washer

q	Remove → Fig.

q	Fit → Fig.

10 -	Outer track, roller bearing

q	Remove → Fig.

q	Fit → Fig.

11 -

Shim

q	For the input shaft

q	Determine thickness → Anchor

12 -	Gearbox casing

q	Repairing → Chapter

13 -	Needle bearing bush

q	Remove → Fig.

q	Before assembling, fit the stop washer → Item

q	Fit → Fig.

14 -	Needle roller bearing

15 -	Sliding 5th gear

q	Remove with the 5th gear syncromesh assembly → Chapter

16 -	Syncromesh ring 5th gear

q	Check wear → Anchor

17 -

Spring

q	Fit → Fig.

18 -	Locking keyways

q	Fit → Fig.

19 -	Syncromesh hub

q	Fit → Fig.

20 -	Sliding sleeve 5th gear

q	Fit → Fig.

21 -	Plate spring

q	Assembly position: The concave side should be facing the 5th gear → Chapter

22 -	Securing screw for 5th gear

q

80 Nm

q	The screw head incorporates a housing for the plate spring → Item

q	Fit → Chapter

Remove the outer track of the roller bearing

Fit the outer track of the roller bearing

Removing the roller bearing

Fitting the roller bearing

Removing the 4th gear, the roller bearing, the stop washer, and the needle bearing bush –  Fit tool -U-40100/3- to the input shaft, under the 4th gear. The 4th gear is removed together with the roller bearing, the stop washer, and the needle bearing bush.

Removing the 3rd gear –  Remove the safety ring with tool -A-81124- before removing the 3rd gear.

Assembling the 3rd gear Assembly position: The collar must be facing the 4th gear. –  Fit safety ring.

Assembling the 4th gear Assembly position: The collar must be facing the 3rd gear.

Fitting the roller bearing –  Fit tool -U-40100/3- under the 2nd gear and locate tool -40200/19- side A facing the roller bearing.

Fit the stop washer and the needle bearing bush –  Fit tool -U-40100/3- under the 2nd gear and locate tool -U-40300/8- side B facing the needle roller bearing.

Remove the outer track of the roller bearing

Fit the outer track of the roller bearing   Note! If the input shaft has been adjusted, the shim must be fitted before assembling the outer track of the roller bearing.

Fit the 5th gear syncromesh assembly Fit the 5th gear syncromesh assembly as follows: –  Fit the sliding sleeve -2- onto the 5th gear syncromesh hub so that the cut-outs -arrow A- coincide for the recess of the syncromesh ring locking keys -4- of both components and that the teeth terminating in the sliding sleeve are located in the same direction with the most pronounced lug -arrow B- of the syncromesh ring locking keys. –  Assemble the syncromesh ring locking keys -4- and fix them with springs -1- at 120° from each other and below the steps of the locking keys.

Fit the springs of the 5th gear syncromesh assembly –  Check that the teeth terminating in end -A- of the sliding sleeve are located in the same direction with the most pronounced lug -B- of the axle box. –  Check that the locking keys are fitted correctly → Fig.. –  Position the springs at 120°, under steps -C- of the locking keys. The angled ends of the springs -arrows- must be outside the locking keys.