SEAT Workshop Service and Repair Manuals

Layshaft: dismantling and assembling

Special tools and workshop equipment required

t	Pliers -A-81124-

t	Kit -T20140-

t	Kit -U-40100-

t	Kit -U-40200A-

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

t	If the layshaft or the roller bearings are replaced, the layshaft must be adjusted → Chapter.

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

1 -	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

2 -

Washer

q	Always 1 mm thick

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

3 -	Outer track, roller bearing

q	Remove → Fig.

q	Fitting → Fig.

4 -	Roller bearings

q	Remove together with 1st gear → Fig.

q	Fitting → Fig.

5 -	Stop washer

6 -	Sliding 1st gear

q	Fitting position → Fig.

7 -	Needle bearing

q	For the sliding 1st gear

8 -	Syncromesh ring

q	Inner ring for 1st gear

q	Checking for wear → Fig.

q	Check that the tabs show no signs of wear

q	Fitting position → Fig.

9 -	Outer ring for 1st gear

q	Fit it to the 1st gear syncromesh ring, item 10

q	Fitting position → Fig.

q	Replace if it shows signs of wear or grooves

10 -	Syncromesh ring 1st gear

q	Checking for wear → Fig.

q	On fitting, the tabs on the ring must fit into their housings in the syncromesh assembly for 1st and 2nd gear → Item

11 -	Safety ring

q	Separation → Fig.

q	Location → Fig.

12 -	Syncromesh assembly for 1st and 2nd gear

q	They are matching pairs

q	Remove → Fig.

q	Assembly of components → Fig. and → Fig.

q	Fitting → Fig.

13 -

Spring

14 -	Sliding sleeve

15 -	Syncromesh hub

16 -	Locking keys

q

3 units

17 -

Spring

18 -	Syncromesh ring 2nd gear

q	Checking for wear → Fig.

q	Fitting position → Fig.

19 -	Outer ring for 2nd gear

q	Fit to syncromesh ring → Item

q	Fitting position → Fig.

q	Replace if it shows signs of wear or grooves

20 -	Syncromesh ring

q	Inner ring for 2nd gear

q	Checking for wear → Fig.

q	Check that the tabs show no signs of wear

q	Fitting position → Fig.

21 -	Sliding 2nd gear

22 -	Safety ring

q	Separation → Fig.

q	Location → Fig.

23 -	Needle bearing

q	For sliding 2nd gear

24 -

3rd gear

25 -	Safety ring

q	Separation → Fig.

q	Location → Fig.

26 -	Safety ring

q	Separation → Fig.

q	Location → Fig.

27 -

4th gear

q	Assembly position: The identification groove should be facing the conical gears

28 -

Layshaft

q	Check that the ratio (number of teeth) is correct → Chapter

q	Adjust → Chapter

29 -	Roller bearings

q	Remove → Fig.

q	Fitting → Fig.

30 -	Outer track, roller bearing

q	Remove → Fig.

q	Fitting → Fig.

31 -

Shim

q	For the layshaft

q	Determine thickness → Chapter

32 -	Clutch housing

33 -	Stop washer

q	The step of the shim should be facing the roller bearing

34 -	Needle bearing bush

q	Removal if ony the needle roller bearing is replaced → Anchor

q	Removal together with 1st gear → Fig.

q

Fitting

35 -	Needle bearing for gear, 5th gear

36 -	Sliding 5th gear

37 -	Syncromesh ring 5th gear

38 -

Spring

q	Fit onto the 5th gear syncromesh ring

q	Replace if it shows signs of wear

39 -	Syncromesh hub 5th gear

q	Removal, fitting and adjustment → Chapter

40 -	Sliding sleeve 5th gear

q	Removal, fitting and adjustment → Chapter

41 -	Safety ring

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.

Fitting 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.

Remove the 1st gear -4- with the roller bearing -3-, the stop washer -2-, and the needle bearing bush for the 5th gear -1- –  Locate tool-U-40100/3- under the first gear.

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.

Removing the 1st and 2nd gear syncromesh assembly –  After removing the safety ring, remove the 2nd gear and the syncromesh assembly as a unit. –  Locate tool -U-40100/3- under the 2nd gear.

Removing the roller bearing –  Locate tool -U-40100/4- under the bearing. –  Locate tool -U-40200/4- over the layshaft and remove the bearing. –  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 roller bearing –  Locate tool -U-40100/3- under the attack gear. –  Place tool -U-40200/19- (side A) over the bearing and secure.

Remove the outer track of the roller bearing –  Remove the layshaft outer roller bearing track from the clutch housing, with tool -T20140-. –  Procedure for extracting the outer track → Anchor.

Fitting the outer track of the roller bearing

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

Checking wear on inner ring for 1st and 2nd gear –  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
1st and 2nd gears	0.75 ... 1.25 mm	0.3 mm

Checking wear on syncromesh ring for 1st and 2nd gear –  Before checking for wear, thoroughly clean the syncromesh rings and their corresponding gears. –  Press syncromesh gear, external ring and internal ring against the cone of the 2nd sliding gear and check dimension “a” with a feeler gauge.

Syncromesh ring	Measurement “a” on a new syncromesh	Wear limit
1st and 2nd gears	1.2 ... 1.8 mm	0.5 mm

Assembly position of external/internal rings and 2nd gear syncromesh –  Fit external ring -A- on 2nd gear. Assembly position: The angled tabs -arrow 1- must be facing the external ring -B-. –  Fit external ring -B-. Assembly position: The tabs -arrow 2- must fit into the cut-outs -arrow 3- of the sliding gear. –  Fit syncromesh ring -C-. Assembly position: The cut-outs -arrow 4- fit into the angled tabs -arrow 1- of the external ring -A-.

Assembly of 1st and 2nd gear syncromesh components –  Fit the sliding sleeve -2- on the syncromesh hub -3- so that the cut-outs of both components coincide. –  Insert the locking keys -4- and secure them with springs -1- at 120° from each other.

Assembly of 1st and 2nd gear syncromesh components –  The angled ends of the springs must locate in the inner hollow of the corresponding locking keys.

Fitting the syncromesh assembly for 1st and 2nd gears Assembly position: The groove -1- for the jaw on the sliding sleeve should be facing 1st gear and the toothed part -2- of the sleeve facing 2nd gear. –  Turn syncromesh gear so that the cut-outs coincide with the locking keys.

Assembly position of the 1st gear external ring Assembly position: The tabs -arows- should face the teeth of the reverse gear -A-.

Assembly position of the 1st gear external ring Assembly position: The tabs -1- should fit into the cut-outs -2- of the syncromesh ring -B-. –  Fit the needle bearing.

Assembly position of the sliding 1st gear Assembly position: The cut-outs of the collar -arrows- should fit into the tabs of the syncromesh ring → Fig.

Fitting the roller bearing –  Position the stop washer between the gear and the roller bearing → Item.