seat Workshop Repair Guides

SEAT Workshop Service and Repair Manuals

ABOUT US
Safety measures for vehicles with start/stop system > < All-wheel drive - notes on performance test

Leon Mk1

General repair notes
General repair notes
Extremely careful way of working as well as the highest possible cleanliness are necessary to ensure the trouble free repairing of the gearbox. Furthermore, the tools must be in perfect condition. Naturally, the customary basic safety rules must be observed during repair work.
A number of generally applicable instructions for the various repair procedures — which were previously repeated at numerous places in the Workshop Manual — are summarised here. They apply to this workshop manual.
Contact corrosion
t  The housing parts may be constructed of a magnesium alloy or an aluminium alloy.
t  Bolts and other components in direct contact with the gearbox have a surface matched to it.
t  Use of inappropriate components (bolts, nuts, washers, etc.) can cause contact corrosion. The housing parts will be damaged.
t  Always install parts listed in the → Electronic parts catalogue „ETKA“.
Front-wheel drive - gearbox
t  When installing the manual gearbox, ensure that the centring sleeves engage correctly between the engine and the gearbox.
t  When installing mounting brackets or waxed components, clean the contact surfaces. Contact surfaces must be free of wax and grease.
t  Allocate bolts and other components using → Electronic parts catalogue „ETKA“.
t  Following installation, check gear oil level → Chapter.
t  Capacity 2.3 l.
All-wheel drive - gearbox
t  When installing the manual gearbox, ensure that the centring sleeves engage correctly between the engine and the gearbox.
t  When installing mounting brackets or waxed components, clean the contact surfaces. Contact surfaces must be free of wax and grease.
t  Allocate bolts. oil and other components using the → Electronic parts catalogue (ETKA).
t  After installation of gearbox or bevel box, check gear oil in gearbox and in bevel box (gearbox → Chapter), (bevel box → Chapter)
   
Capacity, manual gearboxCapacity, bevel box
2.3 litres0.9 litres

Seals and sealing rings
t  Thoroughly clean parting surfaces and apply sealing paste -AMV 188 200 03-.
t  Apply sealant uniformly but not too thick.
t  Renew seals and gaskets.
t  After removing gaskets and seals, always inspect contact surface of housing or shaft for burrs resulting from removal or for other signs of damage.
   
t  Before installing radial shaft seals, lightly oil outer diameter and half-fill space between sealing lips -arrow- with sealing grease -G 052 128 A1-.
t  The open side of the seals should face the liquid to be retained.
t  Following installation, check gear oil level → Chapter.
t  All-wheel drive, checking gear oil in bevel box → Chapter
t  Lightly oil the O-rings before installation, to prevent them from being pressed together during installation.
  N32-0001
Locking devices
t  Renew retaining rings.
t  Do not overstretch retaining rings.
t  Retaining rings must locate properly in grooves.
t  Replace the support sleeves. Installation position: the groove must face parallel to the direction in which force is transferred.
Nuts and bolts
t  Loosen and tighten securing bolts and nuts for covers and housings diagonally.
t  Do not cant especially delicate parts, such as clutch pressure plates. Loosen and tighten bolts and nuts in stages in a diagonal sequence.
t  Torque settings are specified for unoiled bolts and nuts.
t  Always renew self-locking bolts and nuts.
t  Ensure with threaded connections that contact surfaces as well as nuts and bolts are rewaxed only after assembly, if necessary.
t  Use a thread chaser to clear residual locking fluid from all threaded holes into which self-locking bolts are to be screwed. Otherwise, there is a risk of the bolts breaking when next removed
t  Check pitch of thread, to ensure correct thread chaser is used to clean threads and to ensure the threads are not damaged.
Bearing
t  Install new tapered roller bearings as supplied and do not lubricate additionally.
t  Install needle bearings with lettered side (thicker metal) towards fitting tool.
t  Conical roller bearings fitted into one same shaft must be replaced together. They must have the same manufacturer.
t  Use inductive heater -VAS 6414- to heat the inner races of the conical roller bearings to approx. 100°C before installing. Engage to stop without allowing axial clearance.
t  Do not interchange outer or inner races of bearings of the same size. The bearings are matched in pairs. The bearings come in matched pairs.
Shims
t  Check shim settings at various points, using a micrometer. The various thicknesses make it possible to achieve the exact shim thickness required.
t  Check for burrs and damage.
t  Install only flawless shims.
Synchro-rings
t  Do not mix them up. When reusing synchro-rings, always fit to the same synchromeshed gear.
t  Check for wear and renew if necessary.
  A34-0149
t  Check grooves -arrow 1- of synchro-ring -A- and inner ring for flat spots (worn grooves).
t  If synchro-rings are coated, coating must not be damaged.
t  If an intermediate ring -B- is installed, check the outer friction surface -arrow 2- and inner friction surface -arrow 3- of this intermediate ring for »scoring«, »signs of abnormal wear« and »blue discolouration (due to overheating)«.
t  Check cone of synchromeshed gear for »scoring« and »signs of abnormal wear«.
t  Moisten synchromesh mechanism with gear oil before installing.
Gear wheels
t  Before engaging the gear wheels, clean thoroughly and heat to max. 100 °C using the inductive heater -VAS 6414-.
Mobile pinions
t  After assembly, check synchromeshed gears for slight play, or for freedom of movement.
Clutch
t  Ensure that the pressure plate does not cant: loosen and tighten bolts diagonally and in several gradual stages.
t  If the clutch has burnt out, thoroughly clean the clutch housing as well as the friction surface of flywheel with a cloth to reduce the smell of burnt linings.
  N35-10107

Safety measures for vehicles with start/stop system > < All-wheel drive - notes on performance test