SEAT Workshop Service and Repair Manuals

Disassembly and assembly of the input shaft Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Pliers -A 81124-, 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 conical roller bearing –  First remove guide bush → Chapter, Clutch release assembly: repairs.

Install the outer track of the conical roller bearing

Removing the roller bearing

Install the roller bearing

Remove the 4th gear mesh, roller bearing, thrust washer and bush for needle roller bearing. –  Install flat base -U 40100/3- on the input shaft under the 4th gear mesh. The gear of the 4thª gear is removed together with the conical roller bearing, the end washer and the needle bearing sleeve.

Removing the 3rd gear mesh –  Remove the securing ring with pliers -A 81124- before removing the 3rd gear mesh.

Fitting the 3rd gear mesh installation position The gear collar must be facing the 4th gear mesh. –  Fit the securing ring.

Install 4th gear wheel installation position The gear collar should point toward the 4th gear wheel.

Install the roller bearing –  Install flat base -U 40100/3- below the 2nd gear mesh, and position adapter -U 40200/19- side A oriented towards roller bearing.

Fit the attack washer and the bush for gear needle roller bearing –  Install flat base -U 40100/3- below the 2nd gear mesh, and position adapter -U 40300/8- side B oriented towards roller bearing socket.

Remove the outer track of the conical roller bearing

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

Install synchromesh assembly of 5th gear Install the 5th gear synchromesh unit as follows: –  Place the sliding sleeve -2- on the synchromesh bush -3- so that the base strips align -A- in order to house the locking keys -4- of both components, and the teeth terminating in the end of the sliding sleeve are situated in the same direction as the most pronounced lug -B- of the locking keys. –  Install the locking keys -4- and secure them with the springs -1- separating them 120º below the steps of the locking keys.

Install springs in synchromesh assembly of 5th gear –  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 locking pins are correctly installed → Fig.. –  Position the springs separating them 120º, under steps -C- of the locking keys. The angled ends of the springs -arrows- must be outside the locking keys.