SEAT Workshop Service and Repair Manuals

Gearbox, for vehicles with turbo diesel engine. Install Install in reverse order, observing following:   Note t  Clean ATF pipes and ATF cooler before installing a replacement gearbox → Chapter. t  Always replace self-locking nuts and bolts during assembly. t  Renew oil seals, gaskets, O-rings and bolts which are tightened by turning through a specified angle. t  Clean the teeth of the gearbox drive shaft and the teeth of the dual mass flywheel, remove any corrosion and apply a fine layer of grease. Allocation → Spare parts catalogue. It is essential to remove excess grease. t  Secure hose unions with hose clamps the same as those of the series → Current Spare parts catalogue. t  Re-attach all cable ties at the same locations when re-installing. –  Check whether there are adjusting sleeves in the engine for centring the engine/gearbox assembly and fit if necessary. –  Before installing gearbox, tie electrical wiring off to one side so that it cannot be trapped between engine and gearbox. –  Lift gearbox high enough to be able to install selector lever cable.

–  Press selector shaft lever -A- at gearbox to rear as far as it will go -arrow- until parking lock engages.   Note Item -B- can be disregarded.   Note t  Do not bend the selector shaft lever when pressing on the selector lever cable, as otherwise it will no longer be possible to precisely adjust the gear selector mechanism t  Do not bend or twist the selector lever cable. t  Before fitting, lubricate the ball socket of the selector lever cable with polycarbamide grease. Allocation → Spare parts catalogue.

–  Press ball joint of the selector lever cable -1- onto selector shaft lever. –  Tighten the securing screws -2- of the bracket of the selector lever cable -1- to 23 Nm.

–  Carefully lift the gearbox support -T20138C- and move to the fitting position.   Note t  The tightening torques only apply to lightly greased, oiled, phosphated or blackened nuts and bolts (tightening torques → Anchor). t  Additional lubricants may be used, for example engine or gear oils, but they should never contain graphite. t  Use is never to be made of degreased parts. t  Tolerance for tightening torques: ± 15 %. –  Tighten the connecting bolts on the flange between the engine and the gearbox to the specified tightening torque (Tables) → Anchor.

–  Screw the bearing -1- with bolt -2- to the gearbox with the respective tightening torque → Anchor. –  Install ATF pipes with new O-rings → Chapter. –  Install the particulate filter → Exhaust system; Rep. gr.26. –  Fit the complete half-shafts → Running gear, axles, steering; Rep. gr.40. –  Install the cross-member of the gearbox using the respective tightening torque → Chapter. –  Align exhaust system without tension → Rep. gr.26 –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Take all the necessary precautionary measures when connecting the battery → Electrical system; Rep. gr.27. –  Check selector lever cable adjustment → Chapter. –  Check oil level in front final drive → Chapter. –  Check and top up ATF level → Chapter. Securing gearbox to engine (illustration shows gearbox flange)

Vehicles with 2.0 litre turbo diesel engine:

Item	Bolt.	Nm
1	M10x60	45 → Remark
2, 3, 4, 6, 11	M12x67	65 → Remark
5	M12x110	65 → Remark
7	M10x50	45 → Remark
8 … 10	M10x45	45 → Remark
A	dowel sleeves for centring

1)  Renew bolts Specified torques

Component		Nm
Bolts/nuts	M6	10
	M8	20
	M10:	45
	M12	65
Except for the following:
Bracket for selector lever cable to gearbox		23
Drive shaft heat shield to gearbox		23