SEAT Workshop Service and Repair Manuals

Gearbox: removing and installing

Consult the tool and equipment equivalence tables for Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Kit (box) -T20017A-, see equivalent → Anchor

t	Pliers -T20029-, see equivalent → Anchor

t	Holding tool -T20111-, see equivalent → Anchor

t	Holding tool -T20185-, see equivalent → Anchor

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

t	Pressure tool -U-30042-, see equivalent → Anchor

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

t	Holding tool -T20138B-, see equivalent → Anchor

t	Base -T20145-, see equivalent → Anchor

Note t  Cleaning norms when working in the gearbox → Chapter. t  General repair instructions → Chapter. t  Pay attention to the notes relative to the semi-automatic gearbox 02E → Chapter. Gearbox: removing   Note All cable clamps that become loose or cut when removing must be re-installed in the same place when installing. –  Put the gear selector lever into position “P”. –  Remove engine cover → Booklet2. –  Remove the air filter housing, the air hose and the conduit → Rep. Gr.24 and → Rep. Gr.23.   WARNING Take all the necessary precautionary measures when disconnecting the battery → Electrical system; Rep. Gr.27.

–  Remove cover -1- above the battery. To do this press the release tab -arrow-.

–  Disconnect battery earth strap-arrow- with the ignition switched off. –  Remove battery → Electrical system; Rep. Gr.27.

–  Remove battery platform -arrows-.

–  Press the safety washer -A- upwards and remove by turning clockwise. –  Disengage the selector lever cable from the selector rod shaft, following the direction indicated by the arrow and place above. –  Do not loosen the bolt -B-. –  Unscrew both bolts -1-. –  Do not bend the selector lever cable.

–  Removing the starter motor → Electrical system; Rep. Gr.27. –  Unscrew the earth cable -4-. –  Touch the vehicle earth with the hand (without gloves) to release static energy. –  Release the bayonet lock -5- of the 20-contact connector from the gearbox, by turning and disconnecting.   WARNING The gearbox connector contacts should never be touched with the hands, as this may damage the control unit and, therefore, the Mecatronic unit as a result of a discharge of static energy

–  Clamp shut each of the transmission oil radiator hoses using the pressure tool -U-30042- and remove from the radiator -A-. –  Plug the radiator using clean plugs from the kit (box) -T20017A-.

–  Unbolt all the bolts joining the engine and the gearbox which are accessible from above.

–  Position bracket -U-30025E- on bolted flange for wing panels. –  Next, separate the hoses and cables that may be in the area of the engine where the rings that grip the support -U-30025E- go. –  Place eyes onto spindle hooks. –  Pre-tension engine with both spindles uniformly and without raising it. –  Raise the vehicle.

–  Remove central soundproofing, bolts -1 ... 3-.

–  Remove left and right-side soundproofing, bolts -1 ... 3-.

–  Disconnect the electrical connection -2- from the supercharger pressure sender -G31-. –  Screw out bolt -4-. –  Remove the front air duct along with the corresponding hose; to do this, lift the retaining clips slightly -1- and -3-.

–  Remove the right hand side air hose; to do this, lift the retaining clips slightly -arrows-. –  Remove both front wheels.

–  If there is one, remove the protective plate located in the lower section of the gearbox -arrows-. –  Unbolt the two bolts holding the support onto the front section of the gearbox oil sump.   Note The threaded bolts are welded to the oil sump in the front section of the gearbox. –  Separate the support with the threaded bolts from the oil sump, by pressing, and place it above, to ensure it does not get caught up when lowering the gearbox.

–  Remove front crosspiece from vehicle underbody -arrows-.   Note The disconnecting elements in the primary exhaust pipe should not be bent more than 10°. Otherwise they may be damaged. –  Remove the exhaust system by the attachment hose -1-.

–  Unbolt the exhaust system bracket -arrows-.

–  Unbolt the exhaust system bracket -arrows-.

–  Open the clamp -arrow- and remove the primary exhaust tube from the turbocharger.   WARNING Close over the opening in the turbocharger using a clean cloth of spongy material so that coolant and other elements do not enter.

–  Unscrew bolts -1 ... 3- and remove pendular support. –  Remove articulated shafts: → Running gear, shafts, steering; Rep. Gr.40.

From above: –  Unscrew bolts -1- and -2- and detach gearbox console -A-

–  Lower the engine/gearbox using the spindle of the support -U-30025E-....

–  ... until the spacing -a- between the gearbox housing and the gearbox support = 100 ... 110 mm.

–  Unbolt the heat shield for the power steering control unit -J500- from the subframe -arrows-.

–  Connect the support -T20185- onto the subframe in the place of the power steering control unit heat shield and operate the support -T20111- on the engine block. –  Push the engine forwards using the spindle on the support tool. Pay special attention to the following points: l  The alternator should not rub more than lightly on the refrigerant tubes. l  The air conditioning compressor should not rub more than lightly on the refrigerant tube connections. –  Place support tool -T20138B- on base -T20145-, and fit to the hydraulic jack -SAT 1040-.

–  Secure the support tool -T20138B- to the gearbox.   Note t  In gearboxes manufactured after “week 45, 2005”the screw for bar -T20138B/3- cannot be fitted, as the hole has no thread. t  The gearbox is fixed to the two -T20138B/2- bars and supported by bar-T20138B/3-. For this reason take special care when removing the gearbox.

–  Remove gearbox lower securing bolts, disengage gearbox from guide sleeves. –  Regulate counterhold -T20138B- so that gearbox moves without force, at the same time separating gearbox from engine. –  Remove gearbox carefully.