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	Extractor kit -T20140-

t	Adjusting gauge -T20171-

t	Extractor kit -U 40100B-

t	Kit (case) -U-40200A-

t	Kit (case) -U-40300-

Extract the secondary shaft cylindrical roller bearing from the clutch housing –  When removing the bearing, press the securing ring together with pliers -A-.

Insert the cylindrical roller bearing into the clutch housing –  When mounting the bearing, press the securing ring together with pliers -A-. –  Remove the pliers before the bearing is in its final installation position. The securing ring should insert into the slot of the clutch housing.

Release the securing ring -1- from its allotment   WARNING Avoid the uncontrolled release of the securing ring.

Press out the 1st and 2nd gear locking collar and synchronising hub –  After removal of the securing ring, release the 2nd gear mobile pinion and the mobile element with the synchroniser body together.

Installation position of the 3rd and 4th gear mobile pinion –  Fit the 4th gear mobile pinion -A- on the secondary shaft. Fitting position: The collar -arrow 1- must be orientated towards the 3rd gear mobile pinion -B-. –  Fit the securing rings -2- and -3-. –  Fit the 3rd gear mobile pinion -B- on the secondary shaft. Fitting position: The collar -arrow 2- must be orientated towards the 4th gear mobile pinion -A-. –  Fit the securing ring -1-.

Check whether the inner synchromesh ring of 1st and 2nd gear are worn   Note Before measuring the wear of the synchroniser rings, thoroughly clean the rings and their corresponding gears. –  Fit a suitable gauge of the measurement tool -T20171- between the mobile pinion and the inner synchroniser ring. Press the inner ring against the gear cone; the measurement tool -T20171- should move freely.

Synchro-ring	Installation dimension	Wear limit
1. and 2nd gear	0,75 ... 1.25 mm	0.3 mm

Check whether the outer synchromesh ring of 1st and 2nd gear are worn –  Fit the inner synchroniser assembly on the mobile pinion, the measurement tool -T20171- and the outer synchroniser ring. Press the outer ring against the inner synchroniser cone; the measurement tool -T20171- should move freely.

Synchro-ring	Installation dimension	Wear limit
1. and 2nd gear	1.2 ... 1.8 mm	0.5 mm

Installation position of the outer, inner and synchromesh ring for 2nd gear –  Place inner ring -A- on 2nd speed selector gear. –  Angled lugs -arrow 1- face outer ring -B-. –  Fit over the outer ring -B-. The tabs -arrows 2- insert into the grooves -arrows 3- of the mobile pinion. –  Fit over the synchroniser ring -C-. The grooves -arrows 4- insert onto the projections -arrows 1- of the inner ring -A-.

Disassembly and assembly of the mobile element/synchroniser body for the 1st and 2nd gear 1 -  Spring 2 -  Mobile element 3 -  Synchro-hub 4 -  Locking keyways –  Slide locking collar over synchro-hub. Fitting position: After assembly, the groove on the face -arrow A- and the higher shoulder -arrow B- of synchro-hub face outer splines of the locking collar -arrow C-. Deeper notches -arrow D- for locking pieces in synchro-hub and notches -arrow E- in locking collar must align.

Assembly of the mobile element and synchromesh body for 1st and 2nd gear l  Check that the mobile element on the sychronizer body moves without difficulty –  Fit the locking elements in the deepest grooves -arrows- and fit the securing springs off-set by 120º. The folded end of the spring should be located on the inside hollow of the locking element.

Assembly of the mobile element and synchromesh body for 1st and 2nd gear on the secondary shaft. Fitting position: The groove for selector fork that is located on the locking collar must point towards 1st gear; the reverse gear splines point towards 2nd gear. –  Fit the synchroniser ring so that the notches coincide with the locking elements.

Fit retaining ring. –  Install the locking ring for synchronising hub for 1st and 2nd gear on the secondary shaft.

Installation position of 1st gear outer ring –  The tabs -arrows- point towards the teeth of the reverse gear.

Installation position of 1st gear inner ring -A- –  Lugs -arrows 1- locate in notches -arrows 2- of synchro-ring -B-.

Installation position of 1st gear mobile pinion -A- The highest collar -A- should face 2nd gear -B-. Notches in shoulder -arrows- engage in lugs of outer ring → Fig..