SEAT Workshop Service and Repair Manuals

Dismantling and assembling output shaft for 1st and 2nd gear

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	Tube -VW 415 A-

t	Thrust piece -VW 431-

t	Thrust piece -VW 432-

t	Thrust pad -VW 447 i-

t	Tube -VW 516-

t	Tightening plate -30 - 205-

t	Tightening plate -40 - 105-

t	Thrust piece -2050-

t	Thrust pad -3062-

t	Thrust piece -3118-

t	Thrust piece -3401-

t	-1-Internal puller 14.5...18.5 mm, e.g. -Kukko 21/2-

t	-1-Internal puller 46...58 mm, e.g. -Kukko 21/7-

t	-1-Internal puller 56...110 mm, e.g. -Kukko 21/89-

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

t	-4-Counter support , e.g. -Kukko 22/1-

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

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

t	-1-Two arm puller, e.g. -Kukko 20/10-

t	Feeler gauge

t  Thrust piece -T10266-

Pulling dished washer -C- out of output shaft A -  Counter support, e.g. -Kukko 22/1- B -  Internal puller, 14.5…18.5 mm, e.g. -Kukko 21/2-   Note If internal puller slips out of hole in dished washer, use next larger size of internal puller.

Pressing dished washer -A- into output shaft -B- to stop of tool –  Set thrust piece -3401- on dished washer -A- with collar -arrow- on dished washer. Pressing depth of dished washer is then about 2.20 mm. –  Remove retaining ring.

Pulling off tapered roller bearing inner race with 2nd gear synchromeshed gear –  Shift locking collar for 1st and 2nd gear to 1st gear. –  Apply puller hooks behind constant mesh teeth (not dog teeth) of 2nd gear synchromeshed gear. A -  e.g. two arm puller -Kukko 20/10- –  Remove retaining ring.

Pressing off 1st and 2nd gear synchro-hub and locking collar with 1st gear synchromeshed gear   Note Depending on the fit between synchro-hub and output shaft, these parts may be removed by hand in some gearboxes.

Driving off thrust washer -A- for needle thrust bearing –  Clamp output shaft in vice with protective jaw covers -B-. –  Applying a drift -C- on alternate sides, drive thrust washer off output shaft.

Pressing on thrust washer -A- for needle thrust bearing

Installation position of needle thrust bearing –  Set »larger« needle thrust bearing -2- on thrust washer of output shaft -1-. l  Needles must face thrust washer -arrow A- and the smooth side -arrow B- faces upwards. –  Set needle bearing -3- and synchromeshed gear for 1st gear -4- in place. –  Set »smaller« needle thrust bearing -5- on synchromeshed gear for 1st gear. l  Needles must face synchromeshed gear -arrow C- and the smooth side -arrow D- faces upwards.

Checking 1st and 2nd gear inner ring for wear –  Press inner ring onto cone of synchromeshed gear and measure gap -a- using a feeler gauge.

Dimension -a-	Installation dimension	Wear limit
1. and 2nd gear	0.75 … 1.25 mm	0.3 mm

Checking 1st and 2nd gear synchro-rings for wear –  Press synchro-ring, outer ring and inner ring onto cone of synchromeshed gear and measure gap -a- using a feeler gauge.

Dimension -a-	Installation dimension	Wear limit
1. and 2nd gear	1.0 … 1.8 mm	0.5 mm

Installation position of outer ring, inner ring and synchro-ring for 1st gear –  Place inner ring -A- on 1st gear synchromeshed gear. l  The tabs -arrows 1- - must face the outer ring -B-. –  Fit outer ring -B-. l  Lugs -arrows 2- engage in notches -arrows 3- of synchromeshed gear. –  Fit synchro-ring -C-. l  The grooves -arrows 4- insert onto the tabs -arrows 1- of the inner ring-A-. –  Set smaller needle thrust bearing (outer diameter 58.7 mm) -5- on synchromeshed gear for 1st gear. → Fig.

Dismantling and assembling locking collar and synchro-hub for 1st and 2nd gears –  To dismantle, remove springs -1-. 1 -  Spring 2 -  Locking piece 3 -  Locking collar »installation position« → Fig. 4 -  Synchro-hub »installation position« → Fig. –  To assemble, slide locking collar over synchro-hub. l  Installation position: narrower notches in synchro-hub align with notches in locking collar.

Installation position of locking collar Different locking collars are installed:

-A-

Chamfer -arrow 1- faces lower shoulder of synchro-hub.

Shoulder -arrow 2- faces higher shoulder of synchro-hub.

-B-

Shoulder -arrow 3- and shoulder -arrow 4- are the same size = no installation position.

l  Locking collar has been pushed over synchro-hub. –  Insert locking pieces and install springs offset 120°. l  Angled end of spring must locate in hollow locking piece.

Installation position of locking collar with synchro-hub for 1st and 2nd gears High shoulder of synchro-hub -arrow- faces synchromeshed gear for 2nd gear.

Pressing on locking collar and synchro-hub for 1st and 2nd gears and installing retaining ring Insert synchro-ring for 2nd gear so that notches engage in locking pieces of locking collar → Item.

Installation position of 2nd gear outer ring The tabs -arrows- must point towards the unit of the mobile element and synchroniser body -A-.

Installation position of synchro-ring -A- (2nd gear inner ring) Lugs -arrows 1- locate in notches -arrows 2- of synchro-ring -B-. –  Insert needle bearing for 2nd gear synchromeshed gear.

Installation position of synchromeshed gear for 2nd gear Higher shoulder -A- faces 1st gear -B-. Notches in shoulder -arrows- engage in lugs of outer ring → Fig.. –  Press on tapered roller bearing inner race for bearing in clutch housing → Fig..

Pressing on tapered roller bearing inner race for bearing in clutch housing and inserting retaining ring   Note Pull off tapered roller bearing inner race for bearing in gearbox housing → Fig..

Pulling outer race for tapered roller bearing out of gearbox housing A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 46…58 mm, e.g. -Kukko 21/7- –  After pulling out, place new shim with previous value under outer race.

Pressing tapered roller bearing outer race into gearbox housing –  In the process, support gearbox housing using thrust piece -VW 432- directly below bearing support.

Pressing off tapered roller bearing inner race for bearing in clutch housing A -  Splitter 22...115 mm, e.g. -Kukko 17/2-

Pressing on tapered roller bearing inner race for bearing in clutch housing –  Install retaining ring.

Pulling tapered roller bearing outer race out of clutch housing A -  Counter support, e.g. -Kukko 22/4- B -  Internal puller, 56…110 mm, e.g. -Kukko 21/89-   Note t  In order to apply internal puller -B-, collar of oil deflector must first be bent over with a drift. Renew damaged oil deflector. t  After pulling out, renew damaged shim. –  Insert new oil deflector. –  Place new shim with previous value under outer race.

Pressing tapered roller bearing outer race into clutch housing –  Support clutch housing with tube -VW 415 A- directly below bearing support.