SEAT Workshop Service and Repair Manuals

Dismantling and assembling input shaft

Special tools and workshop equipment required

t	Pressure plate -VW 401-

t	Pressure plate -VW 402-

t	Press die. -VW 407-

t	Press die. -VW 408 A-

t	Press die. -VW 412-

t	Thrust piece -VW 454-

t	Assembly sleeve -VW 455-

t	Tube -VW 519-

t	Tube -2040-

t	Thrust pad -3074-

t	-1-Internal puller 37...46 mm, e.g. -Kukko 21/6-

t	-2-Puller, e.g. -Kukko 18/1-

t	-3-Splitter, 22 ... 75 mm, e.g. -Kukko 17/1-

t	-3-Splitter, 22 ... 115 mm, e.g. -Kukko 17/2-

t	-4-Counter support , e.g. -Kukko 22/2-

t	Feeler gauge

Removing retaining ring and pulling cylindrical roller bearing out of clutch housing A -  e. g. Counter support -Kukko 22/2- B -  e.g. Internal puller 37…46 mm -Kukko 21/6-

Pressing cylindrical roller bearing into clutch housing –  Install retaining ring for cylindrical roller bearing. –  Remove retaining ring for cylindrical roller bearing.

Pulling off inner race -D- for cylindrical roller bearing –  Clamp input shaft in vice with protective jaw covers -C-. A -  Puller, e.g. -Kukko 18/1- B -  Splitter 12...75 mm, e.g. -Kukko 17/1-   Note Inner race for cylindrical roller bearing can be pressed off together with gear wheel for 4th gear → Fig..

Pressing off gear wheel for 4th gear l  Installation position of the 4th gear wheel: high shoulder -arrow- must face pressing tool.

Pressing on gear wheel for 4th gear

Insert the inner ring -A- of the cylindrical roller bearing. –  Install retaining ring.

Removing retaining ring and pressing off deep groove ball bearing with 6th gear synchromeshed gear A -  e.g. splitter 22...115 mm -Kukko 17/2- –  Remove retaining ring.

Pressing off synchro-hub and locking collar for 5th and 6th gears with synchromeshed gear for 5th gear

Checking synchro-rings for 5th and 6th gears for wear

-A- = Synchro ring made from brass
Dimension -a-	Installation dimension	Wear limit
5th and 6th gears	1.0 … 1.7 mm	0.5 mm

-B- = Synchro ring made of steel
Dimension -a-	Installation dimension	Wear limit
5th and 6th gears	1.3 … 2.4 mm	0.8 mm

–  Press synchro-ring onto cone of synchromeshed gear and measure gap -a- using feeler gauge.

Dismantling and assembling locking collar and synchro-hub for 5th and 6th gears 1 -  Spring 2 -  Locking piece 3 -  Locking collar 4 -  Synchro-hub –  Slide locking collar over synchro-hub. The recesses of the synchromesh assembly and mobile element must lie over another for the locking elements.

Assembling locking collar with synchro-hub for 5th and 6th gears Locking collar has been pushed over synchro-hub. –  Insert locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece.

Installation position of 5th and 6th gear locking collar and synchro-hub High shoulder of synchro-hub -arrow- faces 5th gear. –  Fit needle bearing. –  Install synchromeshed gear for 5th gear with wave spring washer and synchro-ring.

Pressing on locking collar and synchro-hub for 5th and 6th gears –  Install retaining ring. –  Fit needle bearing. –  Install synchromeshed gear for 6th gear with wave spring washer and synchro-ring. l  Installation position of deep groove ball bearing: the securing clip groove must face upwards -arrow A- and the notch -arrow B- to synchromeshed 6th gear.

Pressing on deep groove ball bearing