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SEAT Workshop Service and Repair Manuals

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Secondary shaft: Disassembling and assembling > < Output shaft

Leon Mk2

Secondary shaft: Assembly overview
Secondary shaft: Assembly overview
  Note
t  Fit the gearbox to the base -T20172/1- along with the tower -T20172/2- and the gear support -T20172/4A- → Chapter.
t  Whenever new gears or shafts are mounted, always consult the technical data → Chapter.
t  Lubricate the bearings, mobile gears and synchromesh rings of the secondary shaft with gear oil.
t  Do not mix up synchromesh rings. If re-using, allocate them to corresponding mobile pinion.
   
1 - Hexagonal nut, tighten to 25 Nm +1/4 turn (90°)
q   4x
q   To secure the bearing housing
2 - clutch housing
q   Repairs → Chapter
3 - Shim
q   For secondary shaft
q   Determining thickness → Chapter
4 - Small tapered roller bearing outer race
q   Removing → Fig.
q   Installing → Fig.
5 - Small roller bearing
q   Removing → Fig.
q   Installing → Fig.
6 - Output shaft
q   Paired with final drive gear wheel. Always renew as a set.
q   In case of replacement
q   Adjusting → Chapter
7 - Tapered roller bearing
q   Removing → Fig.
q   Installing → Fig.
8 - Seal
q   4x
q   Always replace
q   For the securing bolts of the bearing housing → Item
9 - Bearing housing
q   With large primary shaft bearing outer track → Item
q   The external track should only be replaced together with the large roller bearing and the bearing housing
10 - Thrust washer
q   Shoulder of thrust washer faces tapered roller bearing
11 - 1st speed selector gear
q   Before fitting the gear pinion of the 1st gear, install the thrust washer → Item
12 - Needle bearing
q   For the mobile pinion of 1st gear
13 - Inner synchroniser ring for 1st gear
q   Installation position → Fig.
q   Checking for wear → Fig.
q   Check lugs for scoring
14 - Middle synchroniser ring for 1st gear
q   Installation position → Fig.
q   Checking for wear → Fig.
q   Replace if there are signs of scoring and wear
15 - Outer synchroniser ring for 1st gear
q   Identification → Fig.
q   Checking for wear → Fig.
q   Check that the tabs show no signs of wear
16 - Synchronising hub for 1st and 2nd gear
q   Removing → Fig.
q   Dismantling → Fig.
q   Assembly of components → Fig. and → Fig.
q   Installation position → Fig.
q   Installing → Fig.
17 - Circlip
q   Use pliers -A-81124- to remove the safety ring.
q   Always replace
18 - Outer synchroniser ring for 2nd gear
q   Identification → Fig.
q   Checking for wear → Fig.
q   Installation position: The grooves in the synchromesh ring must fit with the pins in the synchromesh assembly of 1st and 2nd gear → Item
19 - Middle synchroniser ring for 2nd gear
q   Fit into the outer synchromesh ring of the 2nd gear → Item
q   Installation position → Fig.
q   Replace if it shows signs of wear or grooves
20 - Inner synchroniser ring for 2nd gear
q   Checking for wear → Fig.
q   Check that the tabs show no signs of wear
q   Installation position → Fig.
21 - 2nd speed selector gear
q   Installation position → Fig.
22 - Needle bearing
q   For the mobile pinion of 2nd gear
23 - Thrust washer
24 - Needle bearing bush
q   Remove together with the 2nd gear mobile pinion → Fig.
q   Installing → Fig.
25 - Needle bearing
q   For the mobile pinion of 3rd gear
26 - 3rd speed selector gear
27 - Syncromesh ring 3rd gear
q   Identification → Fig.
q   Checking for wear → Fig.
28 - 3rd and 4th gear mobile element
q   Removing → Fig.
q   Dismantling → Fig.
q   Assemble → Fig. and → Fig.
q   Installation position → Fig.
q   Installing → Fig.
29 - Needle bearing bush
q   Remove together with the synchromesh assembly of the 3rd and 4th gear → Item
q   Installing → Fig.
30 - Needle bearing
q   For sliding 4th gear
31 - Syncromesh ring for 4th gear
q   Identification → Fig.
q   Checking for wear → Fig.
32 - 4th speed selector gear
33 - Thrust washer
34 - Needle bearing
q   For secondary shaft
q   Removal and installation
35 - Gearbox
36 - Needle bearing bush
q   Removing → Fig.
q   Installing → Fig.
37 - 5th speed selector gear
q   Remove individually → Chapter
q   Remove together with the gearbox housing → Chapter
38 - Bush
39 - 6th speed selector gear
q   Remove individually → Chapter
q   Remove together with the gearbox housing → Chapter
40 - Inner ring of cylindrical roller bearing socket
q   For secondary shaft
q   Apply marking prior to removal
q   Do not confuse with the inner ring of the input shaft roller bearing
q   Can be replaced separately.
41 - Securing bolt of the mobile pinion for the 5th and 6th gear- 40 Nm + 1/2 turn (180°)
q   For secondary shaft
q   Self-locking
q   Always replace

   

Secondary shaft: Disassembling and assembling > < Output shaft