SEAT Workshop Service and Repair Manuals

Secondary shaft for 1st to 4th gear: disassembly and assembly Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Push rod -T20099-, see equivalent → Anchor

t	Extractor kit -T20140-, see equivalent → Anchor

t	Hose clamp -T20141-, see equivalent → Anchor

t	Extractor kit -U 40100B-, see equivalent → Anchor

t	Kit (case) -U 40200A-, see equivalent → Anchor

t	Kit (case) -U 40450A-, see equivalent → Anchor

t	Pliers -A 81124-, see equivalent → Anchor

t	Hose clamp -T20100-, see equivalent → Anchor

t	Push rod -U 40404-, see equivalent → Anchor

Extract the plate washer -A- from the secondary shaft –  Use the installation tool -T20099-.

Insert the plate washer -A- on the secondary shaft –  Insert the plate washer to the limit using the kit (case) -U 40200A- .

Extract the outer ring of the roller bearing from the gearbox casing –  Extract the outer ring of the conical roller bearing of the gearbox casing using the extractor kit -T20140- .

Insert the outer ring of the conical roller bearing from the gearbox casing –  Press the clutch housing directly onto the support tool.

Release the inner ring of roller bearing –  Fit the bridge with bolt -U 40100/1- underneath the interior ring of the conical roller bearings. –  Place the adapter -U 40200/1- between the pressure plate and the drive shaft. Use the press.

Extract the mobile element/synchroniser body for the 3rd and 4th gear along with the 4th gear mobile pinion –  Remove securing ring with pliers -A 81124- before this.

Extract the mobile element/synchroniser body for the 1st and 2nd gear along with the 2nd mobile pinion –  Remove the securing ring. –  Place the bridge with bolt -U 40100/1- underneath the synchroniser for the 1st and 2nd gears, release the mobile pinion and the mobile element/synchroniser body together.

Insert the inner ring of roller bearing –  Place the installation tool -U 40404- underneath the mobile sleeve. –  Place the assembly inside a vice inserting the clamp -T20141- and the adapter -U 40200/12-.

Check the wear of the inner ring of the 1st, 2nd and 3rd gear –  Press the inner ring against the mobile pinion cone and measure the distance -a- with a thickness jig.

Dimension (a)	Assembly level	Wear limit
12., 3. Road speed	0,75 ... 1.25 mm	0,3 mm

Check the wear of the synchronization ring of the 1st, 2nd and 3rd gear –  Press the synchromesh, outer and inner rings against the mobile pinion cone and measure the distance -a- with a thickness gauge.

Dimension (a)	Assembly level	Wear limit
12., 3. Road speed	1,2...1,8 mm	0,5 mm

Installation position of the outer, inner and synchromesh rings for 2ndªgear –  Fit the interior ring -A- onto the mobile pinion for 2nd gear. l  The slanted reinforcements -arrows 1- should face the outer ring -B-. –  Fit over the outer ring -B-. l  The tabs -arrows 2- insert into the recesses -arrows 3- of the mobile pinion. –  Fit over the synchroniser ring -C-. l  The recesses -arrows 4- insert onto the protrusions -arrows 1- of the inner ring -A-

Disassemble and assemble the mobile element/synchroniser body for the 1st and 2nd or 3rd and 4th gear –  To disassemble, the springs must be removed -1-. 2 -  Locking element 3 -  Mobile element 4 -  Synchromesh hub –  To assemble, fit the mobile element onto the synchroniser body. l  Installation position: Narrower recesses in synchronising hub align with recesses in locking collar

Assemble the mobile element/synchroniser body for the 1st and 2nd or 3rd and 4th gear l  Move the mobile element on the synchromesh body. –  Fit locking pieces and install springs offset by 120º. l  The protruding end of the spring should enter into the locking element allotment.

Installation position of the mobile element/synchroniser body for the 1st and 2nd gear l  The gullet -arrow 1- and the thin collar -arrow 2- of the synchroniser body should point to the 1st gear.

Insert mobile element/synchroniser body of the 1st and 2nd gear –  Then fit the securing ring.

Installation position of 1st and 3rd gear exterior ring l  The tabs -arrows- must point towards the mobile element/synchroniser body -A-.

Installation position of 1st and 3rd gear inner synchroniser ring -A-. l  The tabs -arrows 1- insert into the recesses -arrows 2- of the synchroniser ring-B-.

Installation position of the mobile pinion of 1st and 3rd gear The highest collar -A- points towards the 2nd or 4th gear -B-. The collar rebates -arrows- insert into the outer ring tabs.

Installation position of the mobile element/synchroniser body for the 3rd and 4th gear The widest collar of the synchroniser body -arrow- points towards the 3rd gear.

Pressing on 3rd and 4th gear locking collar/synchronising hub –  Then fit the securing ring.

Check 4th gear synchroniser ring for wear. –  Press the inner ring against the mobile pinion cone and measure the distance -a- with a thickness jig.

Dimension (a)	Assembly level	Wear limit
4 gear	1.0..0.10.7 mm	0,5 mm

Insert the inner ring of roller bearing –  Operate the vice until the shaft securing ring can be fitted.

Determining the correct securing ring –  Determine the thickest securing ring that can be fitted and place it → Parts catalogue. The following securing rings are used:

Thickness of the securing ring (mm)
1,79	1,83	1,86
1,89	1,92	1,95
1,98

Remove the outer ring of the roller bearing from the gearbox casing

Fitting the outer ring of the roller bearing into the gearbox casing –  Fit a shim underneath the outer ring –  Support the gear housing directly under the outer ring allotment.