SEAT Workshop Service and Repair Manuals

Removing gearbox   Note t  Cleaning norms when working in the gearbox → Chapter. t  General repair instructions. → Chapter t  Observe notes on dual clutch gearbox (DSG) 02E → Chapter. Removal:   Note All cable clamps that become loose or cut when removing must be re-installed in the same place when installing.   Caution Observe the measures to be adopted when disconnecting the battery → Rep. gr.27.

–  Switch ignition OFF. –  Unplug electrical connector -1- from air mass meter - G70-. –  Remove air hose -2-. –  Screw out bolt -4- and detach air cleaner housing.   Note Possible disregarding of -item 3-. –  Shift selector lever into position „P“. –  Remove battery → Rep. gr.27.

–  Remove battery tray -arrows-.

–  Press the safety washer -A- upwards and remove by turning clockwise. –  Press selector lever cable off selector shaft lever in -direction of arrow- and lift clear. –  Do not loosen the bolt -B-. –  Remove bolts -1-. –  Do not bend or twist the selector lever cable.

–  Unscrew earth connection -3-.   Caution The control unit (mechatronic unit) can be damaged by electrostatic discharge. Do not touch contact pins in gearbox connector with bare hands. –  Touch vehicle earth with your hand (without gloves) to discharge any static electricity. –  Turn the electric connector -4- from the gearbox and remove it.   Note Disregard: -item 1, 2- and the -arrow-. –  Remove starter → Rep. gr.27.

–  Remove the connecting clip -1- –  Throttle the gearbox oil line using the pressure tool - U 30042- and remove the line from the cooler -A-.

–  Seal the radiator using a clean cap -1- from the Set - T20017A -.

–  Unscrew all connecting bolts of the gearbox motor that can be reached from above (-10, 1, 3 and 5-).   Note Bolt -item 3- is located in aperture for starter.

–  Unscrew the nuts -1- of the bracket on the front side of the gearbox oil sump -A-.

–  Remove engine cover

–  Fit the engine and gearbox support -U 30025E- on wing panel flanges and protect them against possible scratches. –  Partly take up weight of engine with spindle, but do not lift.

–  Unscrew bolts -1- and -2- and detach gearbox support -A-.

–  Adjust the spindle of the support -U 30025E- to lower the gearbox to a dimension -a-. l  Dimension -a- ± 120. –  Remove the connection between the steering column and the steering box → Running gear; Rep. gr. 48 –  Raise the vehicle.

–  Remove both front wheels. –  Remove the noise insulation -1 and 3- → Rep. gr.50.

–  Remove left sound insulation -Anchorage parts 1 ... 3-.

–  Unbolt the exhaust system bracket -arrows-.

–  Disconnect the connector -1- from the oil level and temperature sender -G266 -. –  Lock subframe in position prior to removal → Running gear, front-wheel drive and four-wheel drive; Rep. gr. 40. –  Remove subframe with pendulum support → Running gear, front-wheel drive and four-wheel drive; Rep. gr. 40.

–  Unscrew the nuts -2- of the bracket on the front side of the gearbox oil sump -A-.

–  Mark position of propshaft with flexible coupling in relation to bevel box flange. –  Unscrew the cardan shaft with flexible disk from the pair of bevelled gears -arrows-.   Note When slackening off bolts, counterhold propshaft flange/final drive with a suitable lever.

–  Press propshaft horizontally to rear as far as possible.   Caution t  When removing the gearbox, make sure the seal -arrow- on the cardan shaft flange is not damaged. Replace the cardan shaft if the seals are damaged. t  Slackening off bolts for pendulum support/subframe causes engine/gearbox assembly to swing forwards slightly. –  Press the unit to the front a little and separate the cardan shaft from the pair of bevelled gears. –  Tie up the cardan shaft with a belt.

–  Unscrew the insulating panel for the right half shaft from its mounting at the bevelled gears -arrows-. –  Unbolt drive shafts (left and right) from gearbox flange shafts.

–  Push the right and left articulated shafts forwards and fix to the longitudinal member -arrow- with a belt as illustrated in the figure.

–  Unscrew bolts for gearbox carrier on bevel box -arrows 1- and engine -arrows 2-. Do not remove gearbox carrier until gearbox has been pressed off engine.

For removing the dual clutch gearbox (DSG) 02E for four-wheel drive, the gearbox support - T20138C- must be equipped with a bolt -3282/48-. –  Take the fixing bolts from the bevelled gear on the gearbox -1- and replace with a type M10X55 for fixing the arm of the gearbox support -T20138C- to the bevelled gear. –  Align the arm of the of the gearbox support in the direction of the borehole of the gearbox as show in the drawing.

–  Attach the engine and gearbox jack -SAT 1040- and connect the base -T20145- under the vehicle using the hydraulic engine and gearbox jack adapter -SAT 1001/1-. –  Unscrew the remaining connecting bolts of the gearbox motor -6, 7, 8 and 9-. –  Remove the gearbox from the dowel sleeves -A-. –  Pull the gearbox off engine first from the bevel box side and then from the front side. –  Using the hydraulic jack -SAT 1040-, carefully lower the gearbox. in doing so, take care that no cables or lines catch anywhere.