SEAT Workshop Service and Repair Manuals

Gearbox, removing and fitting

Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Hydraulic jack -SAT 1040-, see equivalent → Anchor

t	Torque wrench kit -SAT 8010-, see equivalent → Anchor

t	Gearbox support -T20138C-, see equivalent → Anchor

t	base -T20145-, see equivalent → Anchor

t	Socket -U 30025E-, see equivalent → Anchor

t  Circuit clamp (female) -SAT 1210-, see equivalent → Anchor

t  Circuit clamp (male) -SAT 1211-, see equivalent → Anchor t  Removing → Anchor t  Installing → Anchor t  Tightening torques → Anchor Removing –  Disconnect the earth cable from the battery → Electrical system; Rep. Gr.27.   Note For vehicles fitted with an anti-theft code radio, the code must be found first.

–  Loosen the engine cover at the locations -arrows- and remove. –  Remove air cleaner housing → Rep. Gr.23.   Note Note the relay lever shaft bushes.

–  Remove the safety washer -A- that secures the connector cable to the gear change / idler lever. –  Extract the securing washer -arrow 1- from the relay lever and remove the assembly with the cable -B- from the selector lever cover. –  Remove gear selector/engagement rod; to do this, the nut must be unscrewed -arrow 2-.

–  Unbolt the cable support from gearbox -arrows-. –  Position the cable assembly and lever so that they do not interfere with the subsequent operations.

–  Unplug connector from speed sender -arrow-.

–  Unplug connector from the starter motor -1-. –  Extract the connector for reverse lights -2-. –  Rotate the upper mounting bolt from the starter. -3-. –  Disconnect the hook -4- all the way, and remove the hose.

–  Seal off the pressure conduits of the clutch circuit using the clutch circuit seal (male) -SAT 1211- on the side of the clutch slave cylinder, and using the clutch circuit seal (female) -SAT 1210- on the side of the clutch master cylinder.   WARNING Do not depress clutch pedal after removing slave cylinder.   Note t  Brake fluid is toxic. It should not come into contact with the paintwork due to its corrosive effects. t  When handling the brake fluid hoses, place a large protective cover or cloth with no loose threads under the clutch slave cylinder adaptor.

–  Disconnect the metal clip -1- and remove the left supercharger air hose from the charged air cooler. –  Separate and remove the left air pipe from the exhaust gas turbocharger → Rep. Gr.21. –  Remove the upper bolts joining the engine and the gearbox. –  Separate the hoses and cables that may be in the area of the engine where the rings that grip the support -U 30025E- go.

–  Fit the Support -U-30025E-. The adjustable position of the feet must be inclined to the back -arrow- when doing so.   Note t  Ensure that the pipe connections and the cables in the area where the engine bearing does not suffer any damage while fitting the hooks of the support equipment. t  When placing support -U 30025E-, ensure that the support struts remain well seated in the profile of the wing and the bar of the tool. Find the centre of the mechanical unit without damaging the bodywork. –  Put some force on the drive train using the spindles. –  Remove front left wheel housing moulding → Bodywork, exterior fitting work; Rep. Gr.66. –  Separate the half-shafts from the flange shafts and tie up as far as possible to make sure they are not in the way for upcoming work → Running gear, shafts, steering; Rep. Gr.40. –  Remove the subframe → Running gear, axles, steering; Rep. Gr.40. –  Unscrew lower starter motor fixing bolt and remove starter motor.

–  Loosen the bolts of the double clamp -1- and release the suspension elements -arrows-. –  Remove the fuse holder and its bracket in the engine compartment → Electrical system; Rep. Gr.97.

–  Unscrew the bolts -arrows- for the gearbox mounting -2-. –  Partially lower the engine assembly.

–  Undo the bolts -arrows A, B and C- and remove the gearbox console.

–  Remove the small heat protection plate -A- for the engine flywheel.

–  Attach the support tool -T20138C- on the base -T20145-, and move these onto the engine and gearbox jack -SAT 1040- using the adapter for the hydraulic engine and gearbox jack -SAT 1001/1-. –  Fix the gearbox support -T20138C- to gearbox -arrows- –  Extract the gearbox/engine lower securing bolts, disengage gearbox from guide sleeves.

–  Adjust properly the bolts from the base -T20145- for the gearbox to have a proper incline when lowering. Feed the right flange shaft -A- through in the area of the flywheel / intermediate plate.   Note Take care not to damage the power steering lines and coolant lines when lowering gearbox. Installing Install in reverse order to dismantling, noting the following.   Note t  Clean the splines on the input shaft and lightly lubricate them with grease → Spare Spare parts catalogue. t  It must be possible to move the clutch plate from side to side on the input shaft. t  Check whether there are adjusting sleeves in the engine for centring the engine/gearbox assembly and fit if necessary. t  Ensure that the intermediate plate is correctly seated on the engine. t  Note the power steering lines and the clutch mechanism. In order to install the gear it must be on the bracket -T20138C- on thegear box -T20145- and this must be attached on the engine/ gear jack -SAT 1040- –  Adjust the screws of the base -T20145- respectively so that the gearbox is aligned to the guide sleeves. –  Include gear with the corresponding screws: Tightening torques → Anchor. –  Fit the console and the mount of the gearbox bracket. Tightening torques → Rep. Gr.10.   Note Once the drive train brackets are fitted, tighten with no strain. –  Install the fuse holder and its bracket in the engine compartment → Electrical system; Rep. Gr.97. –  Install the subframe → Running gear, axles, steering; Rep. Gr.40. –  Fit the drive shaft to the gearbox → Running gear, shafts, steering; Rep. Gr.40, –  Fit the exhaust system → Rep. Gr.26. –  Fit the starter motor and secure it with the lower bolt.   Note t  Brake fluid is toxic. It should not come into contact with the paintwork due to its corrosive effects. t  When handling the brake fluid hoses, place a large protective cover or cloth with no loose threads under the clutch slave cylinder adaptor.

–  Remove the clutch circuit clamp (female) -SAT 1210- and the clutch circuit clamp (male) -SAT 1211- from the lines and the clutch slave cylinder.

–  Fit the hoses and secure with the hook -4-. –  Fit the upper securing bolt -3- of the starter motor. –  Connect the starter motor connectors -1- and connect the reverse gear light -2-. Tightening torques

Gearbox on the engine:

Position.	Bolt	Nm
1 → Note → Note, 2 → Note → Note	M12×55	80
3 → Note, 4 → Note	M12×165	80
5 → Note	M12×105	80
6 → Note, 7 → Note	M10×50	40
8 → Note	M10×70	40

1)  M8 threaded pin with bolts 2)  Renew bolt A -  Dowel sleeves to centre –  Install air cleaner housing → Rep. Gr.23. –  Connect the battery earth strap → Electrical system; Rep. Gr.27   Note For vehicles fitted with an anti-theft code radio, enter the code. –  Check the gear oil → Chapter. –  If necessary, purging the clutch control → Chapter. –  Adjust selector mechanism → Chapter.

–  Mount the engine cover at the locations -arrows-.