SEAT Workshop Service and Repair Manuals

Installing gearbox   Note t  Refer to procedure „Removing gearbox“ for required special tools → Chapter. t  Renew self-locking nuts and bolts. t  Replace bolts that are tightened with specified tightening angle. t  All cable ties which were opened or cut during removal must be renewed at the same points. t  Clean input shaft splines and, on used clutch plate, hub splines. Remove corrosion and apply only a very thin coat of clutch plate spline grease -G 000 100- to splines. Then move the clutch plate on the input shaft from side to side, until the hub moves smoothly on the shaft. It is important to remove excess grease. –  If the gearbox is to be renewed, the gearbox selector lever and relay lever must be transferred to the new gearbox. –  Carefully use thread tap to remove any remaining locking fluid from all threaded holes which will accommodate self-locking bolts. –  Clean splines of input shaft and apply a thin coat of grease for clutch plate splines -G 000 100-. The clutch plate must slide easily to and fro on the input shaft. –  If no dowel sleeves for aligning engine and gearbox are fitted in cylinder block, install if necessary. If the dowel sleeves are not fitted, this will lead to gear-change problems, clutch malfunction and in some cases gearbox noise (gears will make rattling noises).

–  Assemble engine and gearbox jack, gearbox support -3282- and adjustment plate -3282/63- for „0CF“ gearbox and mounting elements as follows: –  Place adjustment plate -3282/63- on gearbox support -3282- (adjustment plate only fits in one position). –  Align arms of gearbox support according to holes in adjustment plate. –  Screw in support elements -A- as illustrated on adjustment plate.

–  Align gearbox parallel to adjustment plate and set on engine and gearbox jack. –  Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support. –  Secure gearbox with adapter -3282/64-. –  Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.

Gearbox ends in area of 5th gear (-area A-) and in area of differential (-arrow B-) are facing downwards. –  Then raise gearbox carefully and guide past subframe.   Note Pay attention to all pipes/hoses/wiring when installing the gearbox.

–  Bring gearbox into installation position and install. –  Screw in engine/gearbox connecting bolt -arrow- in area of right-hand drive shaft seal. –  Install lower engine/gearbox securing bolts. –  After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.

–  Fit gearbox bracket -A- with new bolts.

–  Align engine and gearbox in installation position. –  Install new bolt -arrow- for left-hand assembly mounting in gearbox mounting.   WARNING Do not remove support bracket -10-2 A- until all bolts securing the assembly mounting have been tightened to specified torque.

–  Install upper engine/gearbox securing bolts -arrows-. –  Fit earth strap if necessary.

–  Install pendulum support using new bolts → Running gear, axles, steering; Rep. gr.40. –  Install drive shafts → Running gear, axles, steering; Rep. gr.40.

–  Install coupling rod -3- to anti-roll bar -2- on both sides → Running gear, axles, steering; Rep. gr.40.

–  Gearbox for vehicles with start stop system Plug on the connector -1- to the gearbox neutral position sender -G701-. –  Push connector -2- onto reversing light switch -F4-.

–  Install slave cylinder -arrows-. –  Install starter → Electrical system; Rep. gr.27.

–  Install cable support bracket to gearbox. Bolts -arrow A- are accessible from engine compartment. Bolt -arrow B- is accessible from beneath vehicle.

–  Install gearbox selector lever and tighten hexagon nut -4- to specified torque → Item. –  Install relay lever -3- together with cable end-piece → Fig.. –  Spread a small amount of grease on pin of gearbox selector lever. Allocate grease using → Electronic parts catalogue (ETKA). –  Attach gear selector cable -2- to gearbox selector lever. –  Install new clip -1-. –  Adjust selector mechanism → Chapter. –  Fill up gear oil → Chapter. –  If fitted, install noise insulation under engine/gearbox → General body repairs, exterior; Rep. gr.66. –  Install battery tray → Electrical system ; Rep. gr.27. –  Fit the battery → Electrical system; Rep. gr.27. –  Connect battery and follow procedure after connecting battery → Electrical system; Rep. gr.27. –  Install engine cover and air filter → Rep. gr.24.   Note Note radio code for vehicles with coded radio.