SEAT Workshop Service and Repair Manuals

Gearbox: fitting Installation is carried out in reverse order, noting the following:   Note t  If installation work is carried out, replace nuts and self-locking bolts. t  Replace bolts that are submitted to goniometric tightening, along with seals and gaskets. t  Secure hose unions with hose clamps the same as those of the series → Current parts catalogue. t  All cable clamps that become loose or cut when removing the gearbox must be re-installed in the same place when installing.

–  Before continuing with the assembly, ensure that the dowel sleeves -A- are correctly fitted onto the engine block. A : Dowel sleeves for centring –  Before assembling the gearbox check the needle bearing that goes in the crankshaft → Rep. Gr.13. Vehicles with intermediate shaft

–  Replace the seal -1- in the gearbox, if not fitting a new gearbox. All vehicles (continued) –  Place support tool -T20138B- and the base -T20145-on the gearbox. –  Fit the previous assembly onto the hydraulic jack -SAT 1040- and place it in installation position. –  Position the gearbox, checking that no cables or pipes are trapped. Vehicles with intermediate shaft –  The intermediate axle of the right-hand articulated shaft must be correctly fitted in the gearbox axle tooth → Running gear, shafts, direction; Rep. Gr.40. All vehicles (continued) –  Screw in all the bolts that hold the engine to the gearbox. Use new bolts, check tightening torques → Chapter.

–  Fit the bracket assembly as follows: –  Place the gearbox console -A- between the gearbox and the gearbox support.

Fix the gearbox console -A- to the gearbox: –  Replace bolts.

Screws -1-

50 Nm + 90° (1/4 turn)

–  Pull the gearbox upwards, towards the leg of the support, with the help of the securing tool.   WARNING Before screwing the screws to fix the gearbox console to the gearbox support it is necessary for the gearbox support and the console to be aligned totally parallel to each other; otherwise the thread may be damaged. If necessary push the rear part of the gearbox upwards with the aid of a trolley jack.

Fix the gearbox console to the gearbox support -arrows-: –  Replace bolts. –  At the start only hand tighten bolts.   WARNING Do not remove support -U-30025E- until all the bolts on the mechanical assemblies mounting have been tightened to corresponding torque and the subframe has been mounted.

–  Carefully insert the selector lever cable into the selector rod shaft (in the opposite direction to that shown by the arrow). –  Fit the safety washer -A- and lock downwards. –  Do not bend the selector lever cable.

–  Screw the counter support-D- to the gearbox with the selector lever cable: –  Replace bolts -1-.

2 bolts -1-, M8

20 Nm + 90° (1/4 turn)

–  Do not bend the selector lever cable.

–  Bolt the pendulum support to the gearbox using new bolts -pos. 2- and -pos. 3-. –  Assemble the exhaust system → Rep. Gr.26. –  Mount the protector for the right-hand articulated shaft (25 Nm). –  Fit articulated shafts: → Running gear, shafts, steering; Rep. Gr.40.

Fix the gearbox console to the gearbox support -arrows-: –  Tighten bolts to the corresponding torque to fix gearbox console to gearbox support -arrows-.

Bolts -arrows-

100 Nm

–  Place the support onto the threaded bolts of the gearbox oil sump.   Note The threaded bolts are welded to the oil sump in the front section of the gearbox. –  Tighten the two bolts holding the support onto the front section of the gearbox oil sump.

–  Attach the cooling pipes to the transmission oil radiator -A- using the pliers -T20029- and then remove each hose clamp -U-30042-.

–  Mount battery support -arrows-. –  Fit the battery → Electrical system; Rep. Gr.27.

–  With ignition switched off, connect earth connection-arrow-to battery.   WARNING Take all the necessary precautionary measures after connecting the battery → Electrical system; Rep. Gr.27 –  Then check the gear oil level and top up if necessary → Chapter. –  Check the selector lever cable adjustment; adjusting if necessary → Chapter. –  Check the coolant level in the cooling system → Rep. Gr.19.