SEAT Workshop Service and Repair Manuals

Secondary shaft for 1st to 4th gear: dismantling and assembling

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	Pressure tool -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	Pressure tool -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 on the secondary shaft –  Insert the plate washer to the limit using the adapter -U-40200/2-.

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

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

Remove the inner ring of roller bearing –  Fit the adapter -U-40100/3- below the inner ring of the conical roller bearings. –  Fit the adapter -U-40200/1-between the vice and the secondary shaft: For this operation use the vice.

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 adapter -U-40100/3- underneath the synchroniser for the 1st and 2nd gears, release the mobile pinion and the mobile element/synchroniser body together.

Fit 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 gauge.

Dimension -a-	Assembly level	Wear limit
1st, 2nd, 3rd Gear	0.75...10.25 mm	0.3 mm

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

Dimension -a-	Assembly level	Wear limit
1st, 2nd, 3rd Gear	1.2...10.8 mm	0.5 mm

Installation position of the outer, inner and synchroniser ring for the 2nd gear –  Fit the interior ring -A- onto the mobile pinion for 2nd gear. l  The slanted projections -arrows 1- should face the outer ring -B- –  Fit over the outer ring -B-. l  The tabs -arrows 2- fit into the recesses -arrows 3- of the mobile gear –  Fit over the synchroniser ring -C-. l  The recesses -arrows 4- fit 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 -  Moveable sleeve 4 -  Synchroniser body –  To assemble, fit the mobile element onto the synchroniser body. l  Fitting position: the smaller recesses in the synchroniser body must coincide with the depressions of the mobile element

Assemble the mobile element/synchroniser body for the 1st and 2nd or 3rd and 4th gear l  The mobile element is fitted onto the synchroniser 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 rebates -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.

Insert mobile element/synchroniser body of the 3rd and 4th gear –  Then fit the securing ring.

Check 4th gear synchromesh ring for wear. –  Press the sinchro ring against the mobile pinion cone and measure the distance -a- with a thickness gauge.

Dimension -a-	Assembly level	Wear limit
4ª gear	1.0...1.7 mm	0.5 mm

Fit 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.

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

Insert 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.