Seat Leon >> Dismantling and assembling output shaft

Special tools and workshop equipment required

Gears, shafts

  • Tightening plate - VW 402-
  • Die - VW 407-
  • Die - VW 412-
  • Tube element - VW 415 A-
  • Thrust pad - VW 432-
  • Inlay socket - 30 - 100-

 

  • Internal puller - VAS 251 611- or, e.g. internal puller - 1- Kukko 21/5-

Gears, shafts

  • Counter-support - VAS 251 621- or, e.g. counter-support - Kukko 22/1-

Gears, shafts

  • Counter-support - VAS 251 621- or, e.g. counter-support - Kukko 22/1-

Gears, shafts

Pulling cylindrical roller bearing out of clutch housing

  • When pulling out, squeeze together retaining ring -arrow- of cylindrical roller bearing, using pliers -C-.
  1. - Counter-support - VAS 251 621- or, e.g. counter-support - Kukko 22/1-
  2. - Internal puller - VAS 251 611- or, e.g. internal puller - Kukko 21/5-

Extract the roller bearing from the clutch housing

  • Support gearbox housing with tube - VW 415 A- (not visible in figure) directly below bearing support.
  • When pressing in, compress circlip -arrow- for roller bearing using pliers -A-.
  • Remove the pliers before the bearing is in its final installation position. The securing ring should insert into the groove of the clutch pan.

Press out securing ring -1- from its slot

  1. - Protective gloves
WARNING

Ensure retaining ring does not spring out uncontrolled.

Press out the mobile sleeve / synchroniser body of 1st and 2nd gear

  • After removing retaining ring, press off synchromeshed gear for 2nd gear together with locking collar and synchro-hub.

Installation position of 3rd gear and 4th gear

  • Fit 4th gear wheel -A- onto output shaft.

Installation position:

The collar -arrow 1- should face towards the 3rd gear pinion -B-.

  • Fit the securing rings -2- and -3-.
  • Fit 3rd gear wheel -B- onto output shaft.

Installation position:

The collar -arrow 2- should face towards the 4th gear pinion -A-.

  • Fit the securing ring -1-.

Check overall whether synchro-ring of the 1st and 2nd gear and inner ring are worn

  • Press synchro-ring, outer race and inner ring onto cone of synchromeshed gear and measure gap -a- at three points displaced by approx. 120º using feeler gauge.
  • Make a note of average value.

Gears, shafts

Note Always replace inner ring, outer ring and synchro-ring together.

Installation position of the outer, inner and synchromesh rings for 2nd gear

  • Fit the interior ring -A- onto the mobile pinion for 2nd gear.

    Angled lugs -arrow 1- face outer ring -B-.

  • Fit the outer ring -B-.

Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed gear.

  • Fit the synchroniser ring -C-.

The recesses -arrow 4- locate on the tabs -arrow 1- of the inner ring -A-.

Disassembly and assembly of the mobile element/synchroniser body for the 1st and 2nd gear

  1. - Spring
  2. - Mobile element
  3. - Synchromesh hub
  4. - Locking element
  • The locking collar is fitted onto the synchro-hub.

Installation position:

After assembling the unit, the groove of the front part -arrow Aand the highest collar -arrow B- of the synchro-hub should face the exterior cogs of the locking collar -arrow C-.

The deeper grooves -arrow D- of the locking piece in the synchromesh must be aligned with the grooves -arrow E- of the mobile sleeve.

Gears, shafts

Assembling locking collar with synchro-hub for 1st and 2nd gears

  • Locking collar has been pushed over synchro hub.
  • Fit the locking elements in the deepest grooves -arrows- and fit the elastic rings off-set by 120º. Angled end of spring must locate in hollow locking piece.

Insert mobile element/synchroniser body of the 1st and 2nd gear

Installation position:

Groove in locking collar for selector fork faces 1st gear and teeth for reverse gear face 2nd gear.

  • Turn the synchromesh ring so that the notches coincide with the locking elements.

Fitting retaining ring

  • Fit the 1st gear securing ring on the mobile sleeve / synchromesh assembly.

Gears, shafts

Installation position of outer ring for 1st gear

The tabs -arrows- point towards the teeth of the reverse gear -A-.

Installation position of 1st gear inner ring -A-

The tabs -arrows 1- insert into the recesses -arrows 2- of the synchromesh ring -B-.

Installation position of synchromeshed gear for 1st gear

The highest collar -A- should face 2nd gear -B-. Notches in shoulder -arrows- engage in lugs of outer ring (-arrow-)

    Assembly overview - output shaft
    Note When installing new gears or new input shaft, refer to - Electronic parts catalogue (ETKA) and technical data. Install all bearings, synchromeshed gears and synchro-rings on output ...

    See also:

    Brief introduction
    Why wear a seat belt and assume the correct sitting position? For the inflating airbags to achieve the best protection, the seat belt must always be worn properly and the correct sitting position ...