SEAT Workshop Service and Repair Manuals

Input shaft: dismantling and assembling

Special tools and workshop equipment required

t	Pliers -A-81124-

t	Kit -T20140-

t	Kit -U-40100-

t	Kit -U-40200 A-

t	Whenever new gears are fitted consult the technical data → Chapter.

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 -	M8 Torx screw, 40 Nm

2 -	Plate spring

3 -

5th gear

q	Removing and installing → Chapter, assembly sequence

4 -

Washer

q	Always 1 mm thick

q	Fitted to gearboxes manufactured from 07.97, except those bearing the letters DQW

5 -	Outer track, roller bearing

q	Remove → Fig.

q	Fitting → Fig.

6 -	Roller bearings

q	Remove → Fig.

q	Fitting → Fig.

7 -	Gearbox casing

q	In gearboxes manufactured from 07.97, except those bearing the letters DQW, and due to washer → Item the outer track of the roller bearing fits 1 mm lower

8 -	Input shaft

q	Adjust → Chapter

9 -	Needle bearing

q	Lubricate before fitting

10 -	Sliding 3rd gear

q	Remove → Fig.

q	Fitting → Fig.

q	It is fitted together with the sliding sleeve and the 3rd and 4th gear syncromesh hub

11 -	Syncromesh ring 3rd gear

q	Checking for wear → Fig.

12 -	Safety ring

q	Separation → Fig.

q	Location → Fig.

13 -	3rd and 4th syncromesh assembly

q	They are matching pairs

q	Separation → Fig.

q	Assemble → Fig.

q	Fitting the input shaft → Fig.

14 -	Safety ring

q	Separation → Fig.

q	Location → Fig.

15 -	Syncromesh ring 4th gear

q	Checking for wear → Fig.

16 -

4th gear

17 -	Needle bearing

q	Lubricate before fitting

18 -	Stop washer

19 -	Roller bearings

q	Can be removed without tools

20 -

Shim

q	For the input shaft

q	Determine thickness → Chapter

21 -	Outer track, roller bearing

q	Remove → Fig.

q	Fitting → Fig.

22 -	Clutch housing

23 -

Spring

q	Fitting position → Fig.

24 -	Locking keys

25 -	Sliding sleeve

26 -	Syncromesh hub

q	Identiifcation and assembly of hub → Fig.

27 -

Spring

q	Fitting position → Fig.

Remove the outer track of the roller bearing   Note! Between the outer track of the roller bearing and the gearbox casing a 1 mm thick washer is fitted.

Fit the outer track of the roller bearing   Note! Between the outer track of the roller bearing and the gearbox casing, fit first the 1 mm thick washer.

Removing the roller bearing –  Locate tool -U-40100/4- between the bearing and the input shaft gear. –  When the bearing has moved, apply pressure with the press, retighten the bolts of the tool to increase the contact surface with the outer track.

Fitting the roller bearing –  Locate tool -U-40100/3- under the input shaft gear.

Remove the outer track of the roller bearing –  Remove the outer track of the roller bearing with tool -T20140-. –  Procedure for extracting the outer ring → Chapter, General instructions for gearbox repairs.

Fit the outer track of the roller bearing

Separate the safety ring –  Use tool -U-40200/26-.   Caution Be careful when releasing the safety ring as it could sping out and case harm.

Remove the 3rd gear and the 3rd and 4th gear syncromesh assembly The 3rd gear is removed together with the 3rd and 4th gear syncromesh assembly. –  First remove the safety ring. –  Fit tool -U-40100/3- to the input shaft, under the 3rd gear. –  When the bearing has moved, apply pressure with the press, retighten the bolts of the tool to increase the contact surface with the inner track.

Fitting the safety ring   Note! Tool -A-81124- can also be used.

Checking syncromesh ring wear Do not exchange the syncromesh rings of the different gears. –  Before checking for wear, thoroughly clean the syncromesh rings and their corresponding gears. –  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 and 4th gears	1.1 to 1.7 mm	0.5 mm

Assemble the sliding sleeve and the syncromesh hub for 3rd and 4th gear The 3rd and 4th gear syncromesh hub can be identified by a groove -lower arrow-. Assembly position: The shorter teeth under the groove -lower arrow- face the 3rd gear. The upper groove -upper arrow- should be facing the 4th gear.

Assembling the sliding sleeve and the syncromesh hub –  The sliding sleeve if fitted by pushing it onto the syncromesh hub. –  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 –  Fit tool -U-40100/4- to the input shaft, under the 2nd gear. –  Locate tool -U-40200/20- on the 3rd and 4th gear syncromesh assembly as far as it will go. –  The syncromesh locking keys must coincide with the housings in the hub. –  Fit a new safety ring making sure it is correctly seated.