D3E801DDA08-7 Speed Dual Clutch Automatic Gearbox 0AM

Service
Workshop Manual
Altea 2009 ➤ , Altea XL 2009 ➤ ,
Ibiza 2008 ➤ , Ibiza ST 2010 ➤ ,
León 2009 ➤ , Toledo 2013 ➤
7 speed dual clutch automatic gearbox 0AM
Edition 07.2016
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - front differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2016 Seat S.A D3E801DDA08

Altea 2009 ➤ , Altea XL 2009 ➤ , Ibiza 2008 ➤ , Ibiza ST 2010 ➤ , León ...
7 speed dual clutch automatic gearbox 0AM - Edition 07.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Overview of the drive force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Code, engine allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Ibiza 2008 ►, Ibiza ST 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Altea 2009 ►, Altea XL 2009 ►, Leon 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Toledo 2013 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Filling quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Gearbox: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.3 Antifriction bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.4 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.5 O-rings, oil seals and gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.6 Safety locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.7 Bolts, nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.8 Working with tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.9 Information on removing and installing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.10 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.11 Instructions for tow starts and when towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.12 Cleaning norms when working in the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 Safety measures for vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Removing and installing the dual clutch, on gearboxes with date of manufacture up to
05.2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Assembly overview - dual clutch, gearboxes made up to 05.2011 . . . . . . . . . . . . . . . . . . 15
1.2 Removing dual clutch, gearboxes made up to 05.2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3 Adjusting position of engagement bearings for clutches “K 1” and “K 2”, gearboxes made up
to 05.2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4 Installing dual clutch, gearboxes made up to 05.2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2 Removing and installing dual clutch, gearboxes made from 06.2011 onwards . . . . . . . . . . 41
2.1 Assembly overview - dual clutch, gearboxes made as of 06.2011 . . . . . . . . . . . . . . . . . . . . 41
2.2 Removing dual clutch, gearboxes made as of 06.2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.3 Adjusting position of engagement bearings for clutches “K 1” and “K 2”, gearboxes made as
of 06.2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.4 Installing dual clutch, gearbox date from 06.2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3 Removing and installing oil seals at clutch end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1 Selector lever: Emergency release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.1 Vehicles up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.2 Vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2 Selector lever handle: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.1 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.2 Separate selector cuff from selector
Protected handle
by copyright. Copying .for. private
. . . .or. commercial
. . . . . . purposes,
. . . . . .in.part
. . or. in. .whole,
. . . is. not
....... 77
2.3 Removing and installing selector
respect tolever display
the correctness illumination
of information L101 Copyright
in this document. . . . . . by
. .SEAT. . . S.A.
.......... 77
3 Selector mechanism in vehicles up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.1 Overview of selector mechanism up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.2 Removing and installing selector lever cable up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . 79
4 Selector mechanism from 03.2009 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.1 Overview of selector mechanism in vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . 84
Contents i
4.2 Selector lever and selector mechanism with gear selector cable: removing and installing, from
contruction year 03/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.1 Selector lever in “P” position and ignition switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.2 Selector lever in “N” position and ignition switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.3 Selector lever in position “Tiptronic” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.4 Ignition and light switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.5 Selector lever position display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.6 Selector lever control cable: checking and adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.7 Checking function of ignition key removal lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6 Safety note on mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . 94
7 Overview - mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
8 Removing mechatronic unit for dual clutch gearbox J743 ; gearbox is installed . . . . . . . . 97
8.1 Mechatronics for dual clutch gearbox J743 removal; gearbox installed, Ibiza 2008 ►, Ibiza ST
2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.2 Mechatronics for dual clutch gearbox J743 removal; gearbox installed, Altea 2009 ►, Altea
XL 2009 ►, Leon 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
8.3 Removing mechatronic unit for dual clutch gearbox J743 ; gearbox is installed, Toledo 2013
► ...................................................................... 120
9 Moving mechatronic unit for dual clutch gearbox J743 into »removal position« by hand . . 132
10 Installing mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . . . . . . . . . . . . . 134
11 View on selector forks; mechatronic unit is removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
12 Renewing bellows with clutch actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
13 Breather hose of mechatronic unit for dual clutch gearbox J743 : removing and fitting . . . . 148
13.1 Breather hose of mechatronic unit for dual clutch gearbox J743 : removing and fitting, Ibiza
2008 ►, Ibiza ST 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
13.2 Breather hose of mechatronic unit for dual clutch gearbox J743 : removing and fitting, Leon
2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
14 Gearbox : removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
14.1 Gearbox removal, Ibiza 2008 ►, Ibiza ST 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
14.2 Removing gearbox; Ibiza 2008 ► with 1.4 l and 132 kW petrol engine . . . . . . . . . . . . . . . . 156
14.3 Gearbox: removing, Altea 2009 ►, Altea XL 2009 ►, Leon 2009 ► . . . . . . . . . . . . . . . . . . 167
14.4 Remove gearbox, Toledo 2013 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
14.5 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
14.6 Tightening torques to attach the gearbox to the engine and information on the gearbox
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
15 Transporting gearbox and securing to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
16 Gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
16.1 Renewing gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
16.2 Draining and filling hydraulic fluid for mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

1 Notes on gearbox disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
1.1 Overview: gearbox disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2 Dismantling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3 Assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4 Dismantling andProtected
assembling gearbox
by copyright. Copying forhousing . . . . .purposes,
private or commercial . . . . . in. part
. . .or.in. whole,
. . . .is.not. . . . . . . . . . . . . 220
5 Dismantling and assembling clutch housing . . . . . . . . . . . . . . . . . . . S.A.
................. 224
respect to the correctness of information in this document. Copyright by SEAT
6 Dismantling and assembling outer input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
7 ...................................................................... 230
8 Output shaft 1: disassembling and assembling, assembly overview . . . . . . . . . . . . . . . . . . 233
8.1 Dismantling output shaft 1 partially . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
8.2 Dismantling output shaft 1 completely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
8.3 Assembling output shaft 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
ii Contents
8.4 Dismantling and assembling locking collars and synchro-hubs of output shaft 1 . . . . . . . . 243
9 Output shaft 2: disassembly and assembly, assembly overview . . . . . . . . . . . . . . . . . . . . 244
9.1 Dismantling output shaft 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
9.3 Dismantling and assembling locking collars and synchro-hubs of output shaft 2 . . . . . . . . 251
10 Output shaft 3: disassembly and assembly, assembly overview . . . . . . . . . . . . . . . . . . . . 252
10.1 Dismantling output shaft 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
10.3 Dismantling and assembling locking collar and synchro-hub of output shaft 3 . . . . . . . . . . 256
11 Notes on gearbox adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
11.1 Calculating shims for clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
12 Calculating shims for gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
13 Parking Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
13.1 Removing and installing cover for parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
13.2 Removing and installing parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
1.1 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
1.2 Renewing oil seal for left flange shaft by.SEAT. . .S.A.
. . .SEAT
. . .S.A
. .does
. . .not. .guarantee
. . . . . or. accept
. . . . any
. . liability
. . . . with
. . . . . . . . . 296
permitted unless authorised
Contents iii
iv Contents
00 – Technical data
1 Gearbox identification
(ERL003143; Edition 07.2016)
Code, engine allocation ⇒ page 3 .
Capacity ⇒ page 6 .
KHN - Gearbox identification

letters
⇒ page 3
01. 06. 06 - Date of manufac‐
ture: 01.06.06 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
14 - Factory key
13:59 - Time
0026 - Running number
1. Gearbox identification 1
2 Overview of the drive force

The 7-speed dual clutch gearbox 0AM is equipped with 5 shafts.
A1 - Input shaft 1
A2 - Input shaft 2
B1 - Output shaft 1
B2 - Output shaft 2
B3 - Output shaft 3
C - Front final drive
K1 - Dual clutch 1
K2 - Dual clutch 2
M - Engine
T1 - Gear train half 1
❑ With gears 1, 3, 5 and 7
T2 - Gear train half 2
❑ With gears 2, 4, 6 and
reverse gear R
2 Rep. gr.00 - Technical data

3 Code, engine allocation

⇒ “3.1 Ibiza 2008 ►, Ibiza ST 2010 ►”, page 3 .
⇒ “3.2 Altea 2009 ►, Altea XL 2009 ►, Leon 2009 ►”, page 3 .
⇒ “3.3 Toledo 2013 ►”, page 4
3.1 Ibiza 2008 ►, Ibiza ST 2010 ►

When spare parts are required for repair work, the codes of the
gearbox must be observed ⇒ page 1 .
Dual clutch gearbox 0AM
Gearbox: Engine code LWY, MGR, MLH, LKK, LWX, MGQ, MGV, MLN, MPU, PWF, QRD,
MPP, NAY, NQH, MLG, MPN, NAX, NBD, NQN, NUC, QHG, RCW
NTW, PMP, PKT, NQG, NTV, PMN, PMV, PKZ, PWT,
PWA, QQY, QHB PKS, PVZ, QQX, QRE, QHH, RPT
QHA, RPU
Assignment Model Ibiza 2008 ►, Ibiza ST 2010 ►
Engine 1.4 l - 110 kW TSI / 1.6 l - 77 kW SRE 1.2 l - 77 kW TSI 1.6 l - 66 kW CR
1.4 l - 132 kW TSI TDI
Gear ratios Final drive I 71 : 16 = 4,437 79 : 18 = 4,388 78 : 19 = 4,105 71 : 16 = 4,437
for 1st to 4th
gear Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Z2 : Z1 Final drive II 71 : 22 = respect
3,227to the correctness
79 : 24 = 3,291in this document.
of information 78 : 25 = 3,12
Copyright by SEAT 71S.A. : 22 = 3,227
for 5th and 6th
gear
Z2 : Z1 Final drive III 71 : 17 = 4,176 79 : 19 = 4,157 78 : 20 = 3,9 71 : 17 = 4,176
for 7th gear
and reverse
gear
1. gear 63 : 18 = 3,500 64 : 17 = 3,765 64 : 17 = 3,765 63 : 18 = 3,5
2. gear 50 : 22 = 2,272 71 : 30 = 2,366 71 : 30 = 2,366 48 : 23 = 2,086
3. gear 49 : 32 = 1,531 63 : 40 = 1,575 63 : 40 = 1,575 47 : 35 = 1,342
4. gear 46 : 41 = 1,121 61 : 53 = 1,150 60 : 54 = 1,111 42 : 45 = 0,933
5. gear 40 : 34 = 1,176 57 : 48 = 1,187 56 : 49 = 1,142 37 : 38 = 0,973
6. gear 39 : 41 = 0,951 52 : 53 = 0,981 51 : 54 = 0,944 35 : 45 = 0,777
7. gear 35 : 44 = 0,795 47 : 58 = 0,810 46 : 59 = 0,779 32 : 49 = 0,653
Reverse 45 : 22 x 53 : 26 = 30 x 53 : 30 x 53 : 42 : 23 x 53 : 26 =
4.170 3.722
3.2 Altea 2009 ►, Altea XL 2009 ►,

Leon 2009 ►
Gearbox: Engine LSU, MGP, MLF, LST, MGN, MLE, NJZ KHP, LKN, LPK,
code MPM, NAW, NQF, MPL, NAV, NKA, LSS, MGL, MLC,
NTU, PMM, PKR NQE, NTT, PKQ, MPJ, NAT, NQB,
PML, PVX, QQW, NTQ, PMJ, PKN,
QGY PVV, QQU, QGW
Assign‐ Model Altea 2009 ►, Altea XL 2009 ►, Leon 2009 ►
ment
Engine 1.6 l - 75 kW SRE 1.6 l - 77 kW CR TDI 1.8 l - 118 kW TFSI
3. Code, engine allocation 3


Gearbox: Engine LSU, MGP, MLF, LST, MGN, MLE, NJZ KHP, LKN, LPK,
code MPM, NAW, NQF, MPL, NAV, NKA, LSS, MGL, MLC,
NTU, PMM, PKR NQE, NTT, PKQ, MPJ, NAT, NQB,
PML, PVX, QQW, NTQ, PMJ, PKN,
QGY PVV, QQU, QGW
Gear ratios Final 79 : 18 = 4,388 72 : 15 = 4,8 71 : 16 = 4,437 71 : 16 = 4,437
drive I
for 1st to
4th gear
Z2 : Z1 Final 79 : 24 = 3,291 72 : 21 = 3,428 71 : 22 = 3,227 71 : 22 = 3,227
drive II
for 5th
and 6th
gear
Z2 : Z1 Final 79 : 19 = 4,157 72 : 16 = 4,5 71 : 17 = 4,176 71 : 17 = 4,176
drive III
for 7th
gear and
reverse
gear
1. gear 64 : 17 = 3,764 63 : 18 = 3,5 63 : 18 = 3,5 64 : 17 = 3,764
2. gear 72 : 29 = 2,482 48 : 23 = 2,086 48 : 23 = 2,086 50 : 22 = 2,272
3. gear 65 : 38 = 1,710 47 : 35 = 1,342 47 : 35 = 1,342 49 : 32 = 1,531
4. gear 63 : 51 = 1,235 42 : 45 = 0,933 42 : 45 = 0,933 46 : 41 = 1,121
5. gear 60 : 46 = 1,304 37 : 38 = 0,973 37 : 38 = 0,973 40 : 34 = 1,176
6. gear 54 : 51 = 1,058 35 : 45 = 0,777 35 : 45 = 0,777
39 : 41 = 0,951
7. gear 50 : 56 = 0,892 32 : 49 = 0,653 32 : 49 = 0,653 35 : 44 = 0,795
Reverse 29 x 53 : 42 : 23 x 53 : 26 = 42 : 23 x 53 : 26 = 45 : 22 x 53 : 26 =
3.722 3.722 4.170
3.3 Toledo 2013 ►

Gearbox: Engine code NUA, PMT, PKX, PWE, QHF, PKY, PWF, QHG, QRD
QRC
Assignment Model Toledo 2013 ►
Engine 1.4 l - 90 kW TSI 1.6 l - 66 kW CR TDI
Gear ratios Final drive I 72 : 15 = 4,8 71 : 16 = 4,437
for 1st to 4th gear
Z2 : Z1 Final drive II 72 : 21 = 3,428 71 : 22 = 3,227
for 5th and 6th gear
Z2 : Z1 Final drive III 72 : 16 = 4,5 71 : 17 = 4,176
for 7th gear and re‐
verse gear
1. gear 63 : 18 = 3,5 63 : 18 = 3,5
2. gear 48 : 23 = 2,086 48 : 23 = 2,086
3. gear 47 : 35 = 1,342 47 : 35 = 1,342
4. gear 42 : 45 = 0,933 42 : 45 = 0,933
5. gear 37 : 38 = 0,973 37 : 38 = 0,973
6. gear 35 : 45 = 0,777 35 : 45 = 0,777
7. gear 32 : 49 = 0,653 32 : 49 = 0,653


Gearbox: Engine code NUA, PMT, PKX, PWE, QHF, PKY, PWF, QHG, QRD
QRC
Reverse 42 : 23 x 53 : 26 = 3.722 42 : 23 x 53 : 26 = 3.722
3. Code, engine allocation 5

4 Filling quantity
The 7-speed dual clutch gearbox has two separate fluid fillings.
One section is filled with gear oil -arrow A-, the other with hydraulic
fluid -arrow B-.
Filling quantity Gear oil section
In case of repair Oil capacity ⇒ “16 Gearbox oil”, page 194
Gearbox: ♦ No change required
♦ Following a repair, only change if the oil
is drained.
Lubricant Gearbox oil for dual clutch gearbox 0AM

Part number ⇒ Electronic parts catalogue
(ETKA)
Filling quantity Hydraulic oil section in the mechatronic unit

of the dual clutch gearbox - J743-
Initial filling 1 litres
Gearbox: No change required
Lubricant Hydraulic oil
Part number⇒ Electronic parts catalogue
(ETKA)
Further information in the part number designates the container
size.
Caution
Risk of damage to the gearbox.

♦ Only the gear oil for the 7-speed dual clutch gearbox 0AM,
which is available through the replacement parts system,
may be used ⇒ Electronic Parts Catalog“ETKA” .
♦ Other types of oil cause malfunctions and/or failure of the
gearbox.
♦ It is not possible to check the fill level of the hydraulic fluid
part of the mechatronic unit for dual clutch gearbox -
J743- . Before repairs, the breather of the mechatronic unit
for dual clutch gearbox - J743- must be sealed so that no
oil can escape.
♦ Several vehicles have a breather hose mounted on the
mechatronic unit breather. Before assembly work, the
hose must be removed and the breather of the mecha‐
tronic unit of the dual clutch gearbox - J743- must be
sealed to be oiltight.
♦ If any oil escapes from the hydraulic fluid part of the me‐
chatronic unit for dual clutch gearbox - J743- , it is not
possible to replenish it or check the level!
♦ If oil escapes from the gear oil part, it can only be rectified
by changing the gear oil. It is not possible
respect to to
the carry outofainformation in this document. Copyright by SEAT S.A.
correctness
filling level check.
♦ If the level of oil/fluid is too high or too low in either of the
parts, the function of the gearbox will be impaired.

5 General repair instructions

⇒ “5.1 Tools”, page 7
⇒ “5.2 Gearbox:”, page 7
⇒ “5.3 Antifriction bearings”, page 9
⇒ “5.4 Oil”, page 9
⇒ “5.5 O-rings, oil seals and gaskets”, page 9
⇒ “5.6 Safety locks”, page 10
⇒ “5.7 Bolts, nuts”, page 10
⇒ “5.8 Working with tester”, page 10
⇒ “5.9 Information on removing and installing the battery”,
page 11
⇒ “5.10 Safety precautions”, page 12
⇒ “5.11 Instructions for tow starts and when towing”, page 13
⇒ “5.12 Cleaning norms when working in the gearbox”,
page 13
5.1 Tools
Uncertainty often occurs with smaller bolts having low tightening
forces. Torque wrench 2...10 Nm - V.A.G 1783- can be used with
these bolts.
5.2 Gearbox:
The gearbox has a hole in the housing.
– Make sure no small parts drop into this hole during installation
work.
5. General repair instructions 7

– Cover the hole with a cloth before installation work.

Always make sure that no dirt can enter an »open« gearbox.
♦ If gearbox covers have been unbolted or gearbox has no fluid,
do not run Protected
engine.byDo not tow vehicle.
copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ First thoroughly clean
respect to theconnecting points and
correctness of information in this surrounding
document. Copyright by SEAT S.A.
areas and then loosen bolts.
♦ When installing, check for proper seating of dowel sleeves be‐
tween engine and gearbox.
♦ Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use foil or paper. Use only lint-
free cloths.
♦ Only fit clean parts: remove genuine replacement parts from
the packaging only during installation.
♦ If repair work cannot be performed immediately, carefully cov‐
er opened components.

In some vehicles, a cover is fitted over the engaging levers.

The cover prevents dirt getting in.
Fastening torque: 8 Nm
Several vehicles have a breather hose mounted on the Mecha‐

tronic breather -1-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Removing and installing therespect
breather hose: of information in this document. Copyright by SEAT S.A.
to the correctness
♦ Ibiza 2008 ►, Ibiza ST 2010 ► ⇒ page 148

♦ Leon 2009 ► ⇒ page 149
5.3 Antifriction bearings

Never interchange bearing shells of tapered roller bearings. Nev‐
er press ball bearings out or in using balls. Both these will cause
irreparable damage to the bearings during operation of the gear‐
box.
5.4 Oil
The gearbox “0AM” has two oil systems. One oil fill is for gears
and shafts. A second filling for the mechatronic unit for dual clutch
gearbox - J743- .
Both oils are Genuine parts ⇒ page 6 .
Do not use any »additives« in the oil.
Do not re-use oil that has been drained off.
Caution
Be careful when working with oil. Dispose of drained oil prop‐

erly. Take note that one drop of oil can contaminate 1000 litres
of drinking water.
5.5 O-rings, oil seals and gaskets

♦ Always renew O-rings, oil seals and gaskets.

♦ After removing gaskets, check the contact surfaces of the cas‐

ing and shaft for feathering or damage caused by the removal
process.
♦ Thoroughly clean housing joint surfaces before assembling.
♦ Always replace paper gaskets, completely disposing of the
used gasket and thoroughly cleaning the contact surfaces.
♦ Lightly lubricate the outer circumference and sealing lip of oil
seals with gear oil before installing.
♦ Coat the O-rings with gear oil or Vaseline before fitting to avoid
crushing during assembly.
♦ Never use other lubricants in the gear oil area. Otherwise there
is a danger of operation faults in the hydraulic gear mecha‐
nism.
♦ The open side of the oil seal should face the side containing
the fluid.
♦ When installing a new oil seal, position the seal such that the
sealing lip does not contact the shaft in the same place as the
old seal (make use of installation depth tolerances).
♦ Observe rules for cleanliness ⇒ page 13 .
5.6 Safety locks

♦ Do not over-expand safety rings.
♦ Renew circlips which have been damaged or over-tensioned.
♦ Securing rings must be well seated in the groove.
5.7 Bolts, nuts

♦ The bolts are removed in reverse order to the tightening se‐
quence.
♦ If no tightening sequence
Protected by copyright. is for
Copying specified, nuts and
private or commercial bolts
purposes, used
in part or into
whole, is not
fix covers and
permitted casings
unless authorisedshould beSEAT
by SEAT S.A. tightened and
S.A does not loosened
guarantee or acceptinany liability with
stages andrespect
in diagonal pairs.
to the correctness of information in this document. Copyright by SEAT S.A.
♦ Renew self-locking nut.

♦ Bolt threads which are screwed with locking fluid must be
cleaned with a metal brush: instructions ⇒ Electronic Parts
Catalog “ETKA” .
♦ Specified torques given are for unlubricated nuts, bolts and
screws.
5.8 Working with tester

Guided fault location, vehicle self-diagnosis and measurement
module
• Use only SEAT testers: Vehicle diagnostic tester .
Various functions are available in the operating modes Guided
functions and Guided fault finding . The 3 most important
are:
♦ Adapting installation information
♦ Read out the measurement value before the report of the re‐
pair.
♦ Initiating basic adjustment

5.8.1 Read out the measurement value before

the report of the repair.
The measurement value must be read out before one addresses
the customer service department or the importer.
Keep track of the readings in a diagnostic report, so that the re‐
quired gearbox data is available for damage analysis.
5.8.2 Complete basic setting

The mechatronic unit detects other control units in the vehicle by
means of signals on the data bus.
Via this function the mechatronic unit automatically adapts im‐
portant settings. Important configurations and programmed val‐
ues are also taken over again. In this manner the synchronisation
points and the »reference points« for the shift lever and the gear‐
shift mechanisms can be adapted.
– The option Complete basic setting may not be selected:
WARNING
Do not carry out basic adjustment without a reason unless re‐

quested to do so!
♦ when this is requested in the “Guided Fault Finding”,

♦ after correcting a registered fault,
♦ after fitting another gearbox,
♦ after fitting a clutch or
♦ or after you have installed a mechatronic unit.
5.8.3 Removal position, basic setting

With this function, the control elements of the selector mechanism
are “moved to the removal position”. This way the mechatronic
unit is able to be removed. A test drive has to be carried out for
the teaching process after installing aProtected
mechatronic unit.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
5.8.4 Idle run basic setting respect to the correctness of information in this document. Copyright by SEAT S.A.
With this function, the control elements of the selector mechanism
are “moved to the idling position”. This function has to be carried
out before towing a vehicle away.
5.9 Information on removing and installing

the battery
The battery is located in the engine compartment or the luggage
compartment depending on the version of the vehicle. Refer to
manual ⇒ Electrical system; Rep. gr. 27 .
For procedures where the battery removal is implemented, the
battery must only be disconnected where the battery is located in
the luggage compartment.
The safety measures for handling the battery can be viewed in
the instruction ⇒ Electrical system; Rep. gr. 27 .

5.10 Safety precautions

If in the test drives it is necessary to use the tester units, take note
of the following:
WARNING
Accidents can be caused if the driver is distracted by test

equipment or if test equipment is not secured.
Injuries can also be caused if the passenger's airbag is trig‐
gered in a collision.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test and measuring
equipment is not secured.
♦ Always attach testers and measuring instruments to the
rear seat with a strap and have them operated from there
by a second person.
Observe the following precautions to avoid possible injury and/or

damage to the vehicle:
WARNING
Accidents and injury can be caused if a gear is inadvertently

engaged while the engine is running.
♦ Before working on the vehicle while the engine is running,
shift the selector lever into position “P” and apply the park‐
ing brake.
Observe the following precautions to avoid possible injury and/or

irreparable damage to electrical and electronic components:
♦ Disconnect and connect test and measurement equipment
only when the ignition is switched off.
Caution
When disconnecting the battery there is a risk of serious dam‐

age to electronic components:
♦ Observe the correct
Protected by copyright. procedure
Copying for disconnecting
for private or commercial purposes, in partthe
or in bat‐
whole, is not
tery.respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ Always switch off the ignition before disconnecting the

battery.
– Disconnect battery ⇒ Rep. gr. 27 .

5.11 Instructions for tow starts and when tow‐

ing
Caution
Risk of irreparable damage to gearbox.

♦ When the vehicle is towed, the selector lever must be set
to position “N” and the vehicle must not be towed for a
distance of more than 50 km or at a speed in excess of
50 km/h.
Note
It is not possible to start the engine by means of tow-starting, for

instance in the case of insufficient battery charge or if the starter
is not working.
5.12 Cleaning norms when working in the

gearbox
♦ Thoroughly clean unions and adjacent areas before removing.
♦ Clean gearbox and gearbox parts with the cleaner: instruc‐
tions ⇒ Electronic Parts Catalog“ETKA” .
♦ When cleaning, do not use cloths with fibres.
♦ Seal off open lines and connections with clean plugs or sealing
caps immediately.
♦ Place removed parts on a clean surface and cover. Use foil or
paper. Use only lint-free cloths.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components.
♦ Only fit clean parts: only remove replacement parts from pack‐
aging immediately prior to installation.

6 Safety measures for vehicles with

start/stop system
WARNING
Risk of injury due to unintentional starting of the engine on ve‐

hicles with the Start-Stop-System.
♦ For vehicles with activated Start-Stop-System (can be
recognised in the display on the instrument panel), the
engine may start automatically when required.
♦ Therefore, ensure that the Start-Stop system is deactiva‐
ted when working on vehicle (switch ignition off, switch
ignition on again as required).

30 – Clutch
1 Removing and installing the dual
clutch, on gearboxes with date of
manufacture up to 05.2011
Removing and installing dual clutch, gearboxes made from
06.2011 ⇒ page 41 .
Overview:
⇒ “1.1 Assembly overview - dual clutch, gearboxes made up to
05.2011”, page 15 .
⇒ “1.2 Removing dual clutch, gearboxes made up to 05.2011”,
page 17 .
⇒ “1.3 Adjusting position of engagement bearings for clutches K 1
and K 2, gearboxes made up to 05.2011”, page 21 .
⇒ “1.4 Installing dual clutch, gearboxes made up to 05.2011”,
page 34 .
1.1 Assembly overview - dual clutch, gear‐

boxes made up to 05.2011
Caution
Risk of damage from clutch adjustment device.

♦ The clutch is self-adjusting. As the re-adjustment can be
influenced by every gear change jerk, care should be tak‐
en that the clutch does not fall onto the gearbox during
installation.
♦ Apermitted
clutch that
respect has
to the fallen onto
correctness a hard
of information surface
in this orCopyright
document. showsbysigns
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
SEAT S.A.
of damage must not be reinstalled.
1. Removing and installing the dual clutch, on gearboxes with date of manufacture up to 05.2011 15
1 - Securing ring
❑ Always renew after re‐
moval
2 - Hub
3 - Securing ring
moval
4 - Large engaging lever for “K
1”
❑ With large engagement
bearing
❑ Always renew if dual
clutch is renewed.
5 - Small engaging lever for »K
2«
clutch is renewed.
6 - Bolts
moval
❑ 8 Nm + turn +90° further
7 - Mounting
❑ For engaging lever
clutch is renewed.
8 - Bar
❑ For small engaging lev‐
er
❑ Not present in some old‐
er gearboxes
clutch is renewed.
9 - Oil seal
❑ For inner input shaft
❑ Replace ⇒ page 68
10 - Oil seal
❑ For outer input shaft
11 - Outer input shaft
12 - Shim “SK 1”
❑ Determine thickness ⇒ page 21
13 - Shim “SK 2”
❑ Determine thickness ⇒ page 21
14 - Small engagement bearings for »K 2«
❑ Always renew if dualbyclutch
Protected isCopying
copyright. renewed.
for private or commercial purposes, in part or in whole, is not
15 - Dual clutch respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Removing ⇒ page 17
❑ Installing ⇒ page 34
16 Rep. gr.30 - Clutch

1.2 Removing dual clutch, gearboxes made

up to 05.2011
Special tools and workshop equipment required
♦ Hook - 3438-
♦ Engine bung set - VAS 6122-
♦ Support bridge - T10323-

♦ -T10356/5- from assembly tool - T10356A-
♦ Extractor - T10373A-
♦ Thrust pad - T10376-
♦ 1 x cap - 0AM 325 120 A- and 1 x cap - 02M 409 120- , alter‐
native to bung set for the engine - VAS 6122-
Prior condition:
• Gearbox removed and secured to engine and gearbox jack
⇒ page 191 .
• Mechatronic unit for dual clutch gearbox - J743- built into
gearbox.
– Pull off both breather caps -arrows- and close using clean
plugs from engine bung set - VAS 6122- to achieve an oil-tight
seal.
WARNING
With several gearboxes, the breather cap on the mechatronic

unit is destroyed during removal and must be renewed.
It is not possible to check the fill level of the hydraulic fluid sec‐
tion of the mechatronic unit. Before repairs, the breather of the
mechatronic unit must be sealed so that no oil can escape.
If any oil escapes from the hydraulic fluid section of the me‐
chatronic unit, it is not possible to replenish it or check the level!
Renew mechatronic unit if any oil escaped!

– Turn gearbox on engine and gearbox jack upwards together

with clutch..
Note
The clutch is pulled off upwards. The mechatronic unit remains

on the gearbox.
– Remove circlip from hub -arrow-.
– Remove the hub using a hook - 3438- and a screwdriver.
– Remove retaining ring -arrow- for clutch.

If retaining ring cannot be removed:
Note
♦ If the retaining ring cannot be removed it is because the clutch

has »clamped« the retaining ring at the bottom.
♦ In this case, press the clutch slightly down as described in the
following until the circlip is released. Never strike the clutch or
shaft with a hammer!
♦ Always renew circlip.
– Position support bracket - T10323- parallel to gearbox flange

as shown in illustration.
– If necessary, balance out gaps using -T10356/5- , for example.
– Screw in bolts -A- hand-tight.
Note
Secure bolts -A- with nuts as required.
Caution
Risk of damage to the clutch and other components!

• Push down clutch using only very light force.
– To press down, turn spindle against thrust piece - T10376- .
Continuation once retaining ring has been removed:

– Insert puller - T10373A- into clutch
Protected and bore
by copyright. out
Copying clutch.
– Remove the clutch together with the extractor - T10373A- .

– Remove small engagement bearing.

– Remove large engaging lever.
– Loosen the screws and remove the small engaging lever with
bar.
Note
Only a few, »older« gearboxes do not have a clip.
– Remove retainer for engaging lever.

1.3 Adjusting position of engagement bear‐

ings for clutches “K 1” and “K 2”, gear‐
boxes made up to 05.2011
WARNING
If the dual clutch is renewed, the following components must

also be renewed:
♦ Both engaging levers with engagement bearing.
♦ Retainer for engaging lever.
♦ Shims for engagement bearing.
After renewal of the dual clutch and its components, the posi‐
tion of the engagement bearings “K 1 and K 2” must always be
readjusted.
Note
♦ There is no need to adjust anything if all the named parts have

only been removed and reinstalled.
♦ The retaining ring must be renewed in each case.
Brief description
♦ Position of engagement bearings is comparable with clutch
play of a manual gearbox. With this 7-speed dual clutch gear‐
box 0AM, there are tolerances in the pressing system of the
gearbox and gear as well. There are also tolerances in dual
clutches. These tolerances must be taken into account sepa‐
rately during adjustment.
♦ The following procedure first describes how to measure all
necessary dimensions on the gearbox so that the appropriate
shim can be selected. In addition are the tolerances in the
clutch that the manufacturer has already calculated. Toleran‐
ces on gearbox and tolerances in clutch determine thickness
of shim.
♦ Adhere to the sequence of work steps.
Overview - clutch actuation
1 - Small engaging lever for »K

2«
clutch is renewed. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Shim for »K 2« respect to the correctness of information in this document. Copyright by SEAT S.A.
3 - Engagement bearings for

»K 2«
clutch is renewed.
1”
❑ With large engagement
bearing
clutch is renewed.
5 - Shim for “K 1”
6 - Bolts
moval
❑ 8 Nm + 90°
7 - Bar
❑ Not present in some old‐
er gearboxes
clutch is renewed.
8 - Mounting
clutch is renewed.


♦ Depth gauge, digital 300 mm - VAS 6594-
♦ End measuring plate - T10374-
♦ Straightedge - T40100-
Prior condition:
• The gearbox flange must be level to assure good contact with
the ruler.
• Mechatronic unit for dual clutch gearbox - J743- must be in‐
stalled.
• Specified torques
⇒ “1.1 Assembly overview - dual clutch, gearboxes made up
to 05.2011”, page 15
Note
Renew the bolts tightened with specified tightening angle.
Caution

• Mounting for engaging lever and entire mechanism of en‐
gagement bearing must be dry and free of oil or grease.
1st step: Prepare the dual clutch for measurement

– Insert retainer for engaging lever.
– Install the small engaging lever with bar and fix with 2 new
screws. Tightening torque: ⇒ page 16
Note
– Insert large engaging lever.

– Check both engaging levers are seated correctly.
– Install old retaining ring of outer input shaft.


2nd step: Determine dimension “B” for clutches “K 1” and “K 2”.
– Place ruler - T40100- upwards across end of shaft onto gear‐

box flange.
Caution
Risk of false measurements.

♦ The ruler - T40100- should remain in this position for the
following measurements. Do not turn over, do not remove.
– Place digital 300 mm depth gauge - VAS 6594- on top of ruler

- T40100- and position depth gauge rod on outer input shaft.
– Set depth gauge to “0”.
– Position depth gauge rod on retaining ring, as show in dia‐

gram.
– In this position, determine dimension “B1” to retaining ring.
• Example: dimension “B1” = 2.92 mm
– In the opposite position, determine dimension “B2” to retaining

ring.
Note
Do not measure on retaining ring joint. The retaining ring could

be pushed away and falsify the reading.

– Calculate mean value from dimension “B1” and “B2”.
Formula: B1 + B2 2
Example:
• 2.92 + 3.002 = 2.96 mm
• Result: Dimension “B” = 2.96 mm
– Remove and dispose of retaining ring.
3rd step: Determine dimension “A 1” for the engagement bearing

of clutch “K 1”.
Caution

♦ Do not insert any shim!
– Place end gauge - T10374- on large engagement bearing with

large opening upwards.
– To ensure that end gauge - T10374-
Protected sits
by copyright. properly
Copying onor engage‐
for private commercial purposes, in part or in whole, is not
ment bearing, press down and turn end gauge.
• Engagement bearing will turn with end gauge - T10374- .


and position depth gauge rod on outer input shaft.
• Ruler - T40100- is lying upwards across end of shaft on gear‐
box flange.
Caution

– Position depth gauge rod on end gauge - T10374- , as show

in diagram.
– In this position, determine dimension “A 1a” to end gauge -
T10374- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Example: Dimension “A 1respect
a” = 2.61 mm
– In the opposite position, determine dimension “A 1b” to end

gauge - T10374- .
• Example: Dimension “A 1b” = 2.81 mm
– Calculate mean value from dimension “A 1a” and “A 1b”.
Formula: A 1a + A 1b 2
Example:
• 2.61 + 2.812 = 2.71 mm
• Result: Dimension “A 1” = 2.71 mm
step: Calculate installation depth of clutch engagement bearing
“K 1”
Note
On the basis of dimension “A 1” and dimension “B”, the actual

installation depth of the clutch engagement bearing “K 1” is now
calculated based on the following calculus.
Dimension “A 1”
– Dimension “B”
+ Exterior height end gauge - T10374- (51.81 mm; fixed val‐
ue)
= permitted
Actual installation depth of clutch engagement bearing “K
1” respect to the correctness of information in this document. Copyright by SEAT S.A.

Example:
• 2.71 mm – 2.96 mm + 51.81 mm = 51.56 mm
• Result: Installation depth of clutch engagement bearing “K 1”
= 51.56 mm
5th step: Determine clearance of clutch “K 1”
Note
With the actual value and specification for the engagement bear‐
ing installation depth, the clearance of clutch “K 1” is now deter‐
mined using the following calculus.
Actual value of engagement bearing installation depth

– Specification of engagement bearing installation depth
(50.08 mm; fixed value)
= Clearance of clutch “K 1”
Example:
• 51.56 mm – 50.08 mm = 1.48 mm
• Result: Clearance of clutch “K 1” = 1.48 mm

6th step: Determine tolerance of clutch “K 1”

– Take clutch tolerance value from new clutch.
• Example: Read tolerance value on clutch “K 1 = + 0.2”, as
shown in diagram.
7th step: Determine shim “SK 1” thickness
Note
On the basis of the clearance value and clutch tolerance “K 1”,

the thickness of shim “SK 1” is now calculated using the following
calculus.
Clearance of clutch “K 1”
–/+ Clutch tolerance of clutch “K 1”
= Calculated thickness of shim “SK 1”
Example:
• 1.48 mm + 0.20 mm = 1.68 mm
• Result: Calculated thickness of shim “SK 1” = 1.68 mm
– From the shims supplied, measure the required shim and have
it ready for installation.
Calculated
permitted thickness
unless authorised by SEATofS.A.
shim
SEAT S.A does not Available shims
guarantee or accept any liability with
respect to the mm Thickness
correctness of information in this document. inSEAT
Copyright by mmS.A.
0,31 … 0,90 0,80
0,91 … 1,10 1,00
1,11 … 1,30 1,20
1,31 … 1,50 1,40
1,51 … 1,70 1,60
1,71 … 1,90 1,80
1,91 … 2,10 2,00
2,11 … 2,30 2,20
2,31 … 2,50 2,40
2,51 … 2,70 2,60
2,71 … 3,30 2,80
Example:
• Chosen shim thickness = 1.60 mm
Caution
Risk of damage to gearbox

♦ Mark shim “SK 1” and have it ready for assembly.
♦ For adjustment, only this shim “SK 1” may be inserted.
8th step: Determine dimension “A 2” for the engagement bearing

– Only install the smaller engagement bearing.
The small engagement bearing only fits in one position
permitted due to the
4 grooves. respect to the correctness of information in this document. Copyright by SEAT S.A.
– By turning -arrows-, check whether small engagement bearing

is properly installed and that grooves are seated correctly.
Caution


– Place end gauge - T10374- on small engagement bearing with

large opening upwards.

box flange.
Caution


in diagram.
T10374- .
• Example: Dimension “A 2a” = 2.50 mm

gauge - T10374- .
Example:
• 2.50 + 2.542 = 2.52 mm
9th step: Determining installation depth of clutch engagement
bearing “K 2”.
Note
On the basis of dimension “A 2” and dimension “B”, the actual

installation depth of the clutch engagement bearing “K 2” is now
calculated based on the following calculus.
Dimension “A 2”
– Dimension “B” Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
+ Interior height end gauge - T10374- (36.20
respect to the mm;of information
correctness fixed val‐ in this document. Copyright by SEAT S.A.
ue)
= Actual installation depth of clutch engagement bearing “K
2”
Example:
• 2.52 mm – 2.96 mm + 36.20 mm = 35.76 mm
• Result: Installation depth of clutch engagement bearing “K 2”
= 35.76 mm
10th step: Determine clearance of clutch “K 2”.
Note
With the actual value and specification for the engagement bear‐
ing installation depth, the clearance of clutch “K 2” is now deter‐
mined using the following calculus.
Actual value of engagement bearing installation depth

– Specification of engagement bearing installation depth
(34.35 mm; fixed value)
= Clearance of clutch “K 2”
Example:
• 35.76 mm – 34.35 mm = 1.41 mm
• Result: Clearance of clutch “K 2” = 1.41 mm

Eleventh step: Determine tolerance of clutch “K 2”

• Example: Read tolerance value on clutch “K 2 = - 0.2”, as
shown in diagram.
Twelfth step: Determining the shim “SK 2” thickness:
Note
On the basis of the clearance value and clutch tolerance “K 2”,

the thickness of shim “SK 2” is now calculated using the following
calculus.
Clearance of clutch “K 2”
Example:
• 1.41 mm – 0.20 mm = 1.21 mm
Calculated thickness of shim Available shims
mm Thickness in mm
0,31 … 0,90 0,80
0,91 … 1,10 1,00
1,11 … 1,30 1,20
1,31 … 1,50 1,40
1,51 … 1,70 1,60
1,71 … 1,90 1,80
1,91 … 2,10 2,00
2,11 … 2,30 2,20
2,31 … 2,50 2,40
2,51 … 2,70 2,60
2,71 … 3,30 2,80
Example:
•respect
Result: Calculated
to the correctness thickness
of information of shimCopyright
in this document. “SK 2” by =
SEAT1.21
S.A.mm
Caution
Risk of damage to gearbox

♦ Mark shim “SK 2” and have it ready for assembly.
♦ For adjustment, only this shim “SK 2” may be inserted.
The adjusting work has now been completed and the »small« en‐
gagement lever has already been installed. The next step now is
to install the clutch again.
– Install clutch ⇒ page 34 .
1.4 Installing dual clutch, gearboxes made

up to 05.2011
♦ Support bridge - T10323-

• Specified torques
⇒ “1.1 Assembly overview - dual clutch, gearboxes made up
to 05.2011”, page 15
Installation
WARNING

also be renewed:
♦ Retainer for engaging lever.
readjusted ⇒ page 21 .
Note
♦ Replace all bolts tightened with further tightening angle.

♦ The following four work steps are only necessary if the position
of the engagement bearings did not have to be adjusted.
– Insert retainer for engaging lever.
– Install small engaging lever with clip.
Note
– Bolt on engaging lever with 2 new bolts.

Tightening torque: ⇒ page 16

Caution

• The positions of the engagement bearings must be ad‐
justed correctly.
Adjustment can only be performed prior to installing the clutch:
⇒ page 21
Do not continue assembly unless the adjustment is correct!
If no new parts
permitted have
unless been
authorised installed,
by SEAT insert
S.A. SEAT removed
S.A does shims.
not guarantee or accept any liability with
For adjustment, only one shim per engagement bearing may
be installed.
• Clutch components must be free of oil and grease when
installing!
– Insert small engagement bearings with measured shim for “K

2”.
Shim should be under small engagement bearing. Therefore, in‐
sert shim first.
• The small engagement bearing only fits in one position due to

the 4 grooves.

– By turning -arrows-, check whether small engagement bearing

is properly installed and that grooves are seated correctly.
– Fix »large« shim for “K 1” in place with 3 drops of adhesive -

AMV 195 KD1 01- .
This prevents shim from slipping out of its seat when clutch is
inserted.
– Turn back spindle of puller -T10373- .
Caution

en that the clutch does not fall
Protected onto the
by copyright. gearbox
Copying for privateduring
or commercial purposes, in part or in whole, is not
installation. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Install clutch with puller - T10373A- in gearbox, as shown in

diagram.

– If necessary, balance out gaps using -T10356/5- from assem‐
bly tool - T10356- , for example.
Note
– Press on clutch as far as it will go.
Note
One hand must be placed on the clutch when mounting. A slight

»rattling« will be felt. Rattling indicates that the clutch is being
pressed onto its press seat. This also enables detection of the
limit stop once the clutch has been seated correctly.
– Take hold of new retaining ring with retaining ring pliers, as

shown in the illustration.
• Mounting position: With the top gap of the circlip facing up‐
wards.
– Insert circlip -arrow-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
If the retaining ring cannot be inserted, the clutch has not been
pressed in onto its limit stop.
– To bring the clutch to the service position, hold the spindle of

the puller - T10373A- firmly with one hand and pull the clutch
with the other hand in the opposite direction of the circlip in the
direction of rotation -arrow-.

Note
♦ By pressing on, the clutch sits at the bottom against the limit
stop on the input shaft. This is not the optimum position.
♦ Clutch should only be pulled up far enough for it to contact
retaining ring.
Note
Only turn by hand. In this way, clutch slides against retaining ring.
Do not use any other tool.
– Insert hub.
• Hub has »large tooth« -arrow- and only fits in one position.
• »Large tooth« has a mark at engine end.
– Insert retaining ring -arrow- of hub.

• Joint of retaining ring must point towards »hub« of clutch.
– Turn clutch by hand and observe small engaging lever whilst

turning.
• While the clutch is being turned, it must be ensured that the

small engaging lever remains absolutely still. It must be en‐
sured that it does not move up and down.
Note
♦ If an engaging lever moves up and down, then shim is not

properly seated.
♦ In this case, the clutch column must be remounted
⇒ page 17 .
♦ Check shims -arrows-.
♦ The shims must be properly seated and must not be damaged.
– Remove two plugs and put breather caps -arrows-on.
WARNING Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Dispose of excess shims.

– After installation of gearbox, perform Complete reset by
means of Guided functions ⇒ Vehicle diagnostic tester.

2 Removing and installing dual clutch,

gearboxes made from 06.2011 on‐
wards
Removing and installing dual clutch, gearboxes made up to
05.2011 ⇒ page 15 .
Overview:
⇒ “2.1 Assembly overview - dual clutch, gearboxes made as of
06.2011”, page 41 .
⇒ “2.2 Removing dual clutch, gearboxes made as of 06.2011”,
page 43 .
⇒ “2.3 Adjusting position of engagement bearings for clutches K 1
and K 2, gearboxes made as of 06.2011”, page 48 .
⇒ “2.4 Installing dual clutch, gearbox date from 06.2011”,
page 61 .
2.1 Assembly overview - dual clutch, gear‐

boxes made as of 06.2011
Caution

installation.
♦ A clutch that has fallen onto a hard surface or shows signs
of damage must not be reinstalled.
2. Removing and installing dual clutch, gearboxes made from 06.2011 onwards 41
1 - Mounting
❑ For large engaging lever
“K 1”
❑ Cannot be renewed.
2 - Ball head studs
❑ Small small engaging
lever “K 2”
clutch is renewed.
3 - Shim “SK 1”
❑ Determine thickness
⇒ page 48
4 - Shim “SK 2”
❑ Determine thickness
⇒ page 48
5 - Small engagement bear‐
ings for “K 2”
clutch is renewed.
6 - Dual clutch
7 - Securing ring
moval
8 - Hub permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
9 - Securing ring
❑ Replace
10 - Large engaging lever for
“K 1”
❑ With engagement bearing
❑ Always renew if dual clutch is renewed.
11 - Upper section of bushing
❑ Small small engaging lever “K 2”
❑ Is removed and installed together with lower section of bushing
12 - Small engaging lever for “K 2”
❑ Is removed and installed together with upper and lower section of bushing
13 - Bolts
❑ Always renew after removal
❑ 8 Nm + 90°
14 - Lower section of bushing
❑ Is removed and installed together with upper section of bushing
15 - Oil seal
❑ For inner input shaft
16 - Oil seal
❑ For outer input shaft

2.2 Removing dual clutch, gearboxes made

as of 06.2011
♦ Hook - 3438-
♦ Support bridge - respect
T10323-
♦ 1 x cap - 0AM 325 120 A- and 1 x cap - 02M 409 120- , alter‐
native to bung set for the engine - VAS 6122-
Prior condition:
• Gearbox permitted
removed and
unless secured
authorised toS.A.
by SEAT engine
SEAT S.Aanddoesgearbox jack
not guarantee or accept any liability with
⇒ page 191 . respect to the correctness of information in this document. Copyright by SEAT S.A.
• Mechatronic unit for dual clutch gearbox - J743- built into
gearbox.
– Pull off both breather caps -arrows- and close using clean
plugs from engine bung set - VAS 6122- to achieve an oil-tight
seal.
WARNING

Renew mechatronic unit if any oil escaped!


tronic breather -1-.
– Removing the breather hose:
♦ Leon 2009 ► ⇒ page 149
All vehicles (continued):

– Turn gearbox on engine and gearbox jack upwards together
with clutch..
Note
The clutch is pulled off upwards. The mechatronic unit remains

on the gearbox.
– Remove circlip from hub -arrow-.
– Remove the hub using a hook - 3438- and a screwdriver.
Note
If parts of clutch are renewed, the position of engagement bear‐

ings “K 1” and “K 2” must be set later. It is therefore advisable to
determine dimension “B” for the measurements now
⇒ page 48 .
– Remove retaining ring -arrow- for clutch

.
If retaining ring cannot be removed:
Note
♦ If the retaining ring cannot be removed it is because the clutch

has »clamped« the retaining ring at the bottom.
♦ In this case, depress the clutch slightly as described in the
following. The retaining ring is thus relieved. Never strike the
clutch or shaft with a hammer!

– If necessary, balance out gaps using -T10356/5- , for example.
Note
Caution
Risk of damage to unless
permitted the clutch and
authorised other
by SEAT S.A. components!
SEAT S.A does not guarantee or accept any liability with
• Push down clutch using only very light force.
– To press down, turn spindle against thrust piece - T10376- .
WARNING
It is not permissible to reuse the retaining ring.
Note
Do not dispose of the retaining ring, if later the dimension “B” must
be determined for adjusting the clutch engagement.
Continuation once retaining ring has been removed:

– Insert puller - T10373A- into clutch and bore out clutch.

– Remove the clutch together with the extractor - T10373A- .
– Remove »large« engagement lever together with »small« en‐

gagement bearings.
Note
The upper section of bushing cannot be removed or installed

alone. It is always removed or installed together with lower section
of bushing and »small« engagement lever.
– Undo and remove bolts and remove »small« engagement lev‐

er together with upper and lower section of bushing.
If no parts are renewed, the ball stud -2- remains installed.
WARNING
The hinge mounting -1- cannot be removed.
Note
If dimension “B” has already been determined, it is now possible

to proceed with step “2” of the measurement ⇒ page 53
2.3 Adjusting position of engagement bear‐

ings for clutches “K 1” and “K 2”, gear‐
boxes made as of 06.2011
WARNING

also be renewed:
♦ Ball-head pin for engaging lever “K 2”.
readjusted.
Note
♦ There is no need to adjust anything if all the named parts have

only been removed and reinstalled.
♦ The retaining ring must be renewed in each case.
Brief description
♦ Position of engagement bearings is comparable with clutch
play of a manual gearbox. With this 7-speed dual clutch gear‐
box 0AM, there are tolerances in the pressing system of the
gearbox and gear as well. There are also tolerances in dual
clutches. These tolerances must be taken into account sepa‐
rately during adjustment.
♦ The following procedure first describes how to measure all
necessary dimensions on the gearbox so that the appropriate
shim can be selected. In addition are the tolerances in the
clutch that the manufacturer has already calculated. Toleran‐
ces on gearbox and tolerances in clutch determine thickness
of shim.
♦ Adhere to the sequence of work steps.
Overview of clutch actuation:

1”
❑ With engagement bear‐
ing
clutch is renewed.
3 - Mounting
❑ For large engaging lever
“K 1”
❑ Cannot be renewed.
4 - Small engagement bear‐
ings for “K 2”
clutch is renewed.
6 - Upper section of bushing
lever “K 2”
❑ Is removed and installed
together with lower sec‐
tion of bushing
7 - Small engaging lever for “K
2”
❑ Is removed and installed
together with upper and
lower section of bushing
clutch is renewed.
8 - Ball head studs
lever “K 2”
❑ Always renew if dual clutch
Protected is renewed.
9 - Bolts respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ 8 Nm + 90°
10 - Lower section of bushing
❑ Is removed and installed together with upper section of bushing

♦ End measuring plate - T10466-
♦ Straightedge - T40100-
Prior condition:
• The gearbox flange must be level to assure good contact with
the ruler.
• Mechatronic unit for dual clutch gearbox - J743- must be in‐
stalled.
Caution

• Mounting for engaging lever and entire mechanism of en‐
gagement bearing must be dry and free of oil or grease.
– Remove installed ball stud using pliers.

– Push in »new« ball stud by hand, if necessary using a plastic

hammer and drift to tap it in.
Note
Tap on the mandrel lightly using a hammer. Otherwise the ball

stud may be impaired.
– Install old retaining ring of outer input shaft.
1st step: Determine dimension “B” for clutches “K 1” and “K 2”.
– Place ruler - T40100- upwards across end of shaft onto gear‐

box flange.
Caution

following measurements. Do not turn over,
Protected do not
by copyright. remove.
Copying for private or commercial purposes, in part or in whole, is not

- T40100- and position depth gauge rod on outer input shaft.
– Position depth gauge rod on retaining ring, as show in dia‐

gram.
– In this position, determine dimension “B1” to retaining ring.
– In the opposite position, determine dimension “B2” to retaining

ring.
Note
Do not measure on retaining ring joint. The retaining ring could

be pushed away and falsify the reading.
• Example: dimension “B2” = 2.58 mmunless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted
– Calculate mean value from dimension “B1” and “B2”.
Formula: B1 + B2 2
Example:
• 2.62 + 2.582 = 2.60 mm
• Result: Dimension “B” = 2.60 mm
Note
If the dual clutch is still in place after this measurement, it must

now be removed ⇒ page 46 .

– Remove and dispose of outer input shaft.
WARNING
It is not permissible to reuse the retaining ring.
2nd step: Determine dimension “A 1” for the engagement bearing

of clutch “K 1” .
WARNING
– Check that engaging lever is seated correctly.
– Place end gauge - T10466- on large engagement bearing. The

flat side must point upwards.
– To ensure that endpermitted
gauge - T10466-
unless sits
authorised by SEATproperly
S.A. SEAT on engage‐
S.A does not guarantee or accept any liability with
ment bearing, press down and
respect to theturn end gauge.
correctness of information in this document. Copyright by SEAT S.A.

box flange.
Caution


in diagram.
T10466- .

gauge - T10466- .
Example:
• 4.93 + 4.912 = 4.92 mm
3rd step: Determine height tolerance for the engagement bearing
Note
On the basis of dimension “A 1” and dimension “B”, the height

tolerance of the clutch engagement bearing “K 1” is now calcula‐
ted according to the following calculus.
Dimension “A 1”
= Actual height tolerance of clutch engagement bearing “K
1”
Example:
• 4.92 mm – 2.60 mm = 2.32 mm
• Result: Height tolerance of clutch engagement bearing “K 1”
= 2.32 mm


• Example: Read tolerance value on clutch “K 1 = + 0.2”, as
shown in diagram.
5th step: Determine shim “SK 1” thickness
Note
On the basis of the clutch tolerance “K 1”, the thickness of shim

“SK1” is now calculated according to the following calculus.
Height tolerance of engagement bearing “K 1”

Example: respect to the correctness of information in this document. Copyright by SEAT S.A.
• 2.32 mm + 0.20 mm = 2.52 mm

– Select required shim from the table with the help of the part
number -magnifying glass- and have it ready for installation.
Calculated thick‐ Available shims Part number of shim
ness of shim Thickness in mm
mm
1,21 … 1,60 1,50 0AM 141 383
1,61 … 1,80 1,70 0AM 141,383 A
1,81 … 2,00 1,90 0AM 141.383 B
2,01 … 2,20 2,10 0AM 141 383 C
2,21 … 2,40 2,30 0AM 141 383 D
2,41 … 2,60 2,50 0AM 141 383 E
2,61 … 2,80 2,70 0AM 141 383 F
2,81 … 3,00 2,90 0AM 141 383 G
3,01 … 3,20 3,10 0AM 141 383 H
3,21 … 3,40 3,30 0AM 141.383 J
3,41 … 3,80 3,50 0AM 141.383 K
Example:
• Chosen shim thickness = 2.50 mm = part number DAM 141
383 E
WARNING
To avoid damage to clutch, only fit this shim later.
– Remove end gauge - T10466- and large engagement lever

again.
6th step: Determine dimension “A 2” for the engagement bearing

Observe the following when
permitted unless installing
authorised by SEATa new
S.A. engaging
SEAT S.A does not lever »K2«:
The new engaging lever »K2« with upper and lower section of
guide sleeve will be delivered in transport position -illustration-
and must be set to installation position prior to installation.
Setting engaging lever »K2« to installation position:

– Hold upper section of guide sleeve with one hand. With the
other hand turn the lower section of guide sleeve in direction
of arrow until the sleeve moves freely.
Note
Apply high force to hold both sections, as this is necessary for

turning the lower section of the guide sleeve.
If the engaging lever is in installation position, the holes of the

lower section of guide sleeve are at right angles to the engaging
lever and the sleeve moves freely.
Continued for all vehicles:
– Install »small« engagement lever together with upper and low‐

er section of bushing. Insert and tighten new bolts.
– »Insert small« engagement bearing.
• The small engagement bearing only fits in one position due to

the 8 grooves.
– By turning, check whether small engagement bearing has
been installed correctly and that grooves are seated correctly.
Caution

– Place end gauge - T10466- on small engagement bearing.

The flat side should face upwards.
– To ensure that end gauge - T10466- sits properly on engage‐
ment bearing, press permitted
down and turn end gauge.


box flange.
Caution



in diagram.
T10466- .

gauge - T10466- .
Example:
• 4.79 + 4.752 = 4.77 mm
7th step: Calculate height tolerance of clutch engagement bearing
“K 2”.
Note
On the basis of dimension “A 2” and dimension “B”, the height

tolerance of the clutch engagement bearing “K 2” is now calcula‐
ted according to the following calculus.
Dimension “A 2”
= Actual height tolerance of clutch engagement bearing “K
2”
Example:
• 4.77 mm – 2.60 mm = 2.17 mm
• Result: Height tolerance of clutch engagement bearing “K 2”
= 2.17 mm

• Example: Read tolerance value on clutch “K 2 = - 0.2”, as
shown in diagram.
9th step: Determine shim “SK 2” thickness:
Note
On the basis of the clutch tolerance “K 2”, the thickness of shim

“SK 2” is now calculated according to the following calculus.
Height tolerance of engagement bearing “K 2”

Example:
• 2.17 mm – 0.20 mm = 1.97 mm
Calculated thick‐ Available shims Part number of shim
ness of shim Thickness in mm
mm
0,31 … 0,90 0,80 WHT 005 518
0,91 … 1,10 1,00 WHT 005 518 A
1,11 … 1,30 1,20 WHT 005 518 B
1,31 … 1,50 1,40 WHT 005any 518 C with
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept liability
1,51 … 1,70 1,60 WHT 005 518 D
1,71 … 1,90 1,80 WHT 005 518 E

1,91 … 2,10 2,00 WHT 005 518 F
2,11 … 2,30 2,20 WHT 005 518 G
2,31 … 2,50 2,40 WHT 005 518 H
2,51 … 2,70 2,60 WHT 005 518 J
2,71 … 3,30 2,80 WHT 005 518 K
Example:
WARNING
To avoid damage to clutch, only fit this shim later.
The adjusting work has now been completed and the »small« en‐
gagement lever has already been installed. The next step now is
to install the clutch again.
– Install clutch ⇒ page 61 .

2.4 Installing dual clutch, gearbox date from

06.2011
♦ Support device - T10323-
Installation
Caution

also be renewed:
♦ Ball-head pin for engaging lever “K 2”.
The hinge mounting cannot be removed.
readjusted ⇒ page 48 .
Hinge mounting -1- and ball stud -2- have been installed.
Note
The upper section of bushing cannot be removed or installed

alone. It is always removed or installed together with lower section
of bushing and »small« engagement lever.
The following work is only necessary if all the named parts have
merely been removed and reinstalled.
– Install »small« engagement lever together with upper and low‐
er section of bushing. Insert and tighten new bolts.
Continued for all vehicles:
Caution

• The positions of the engagement bearings must be ad‐
justed correctly.
Adjustment can only be carried out before the clutch is instal‐
led.
Do not continue assembly unless the adjustment is correct!
If no new parts have been installed, insert removed shims.
For adjustment, only one shim per engagement bearing may
be installed.
• Clutch components must be free of oil and grease when
installing!

– Insert »large« engaging lever with measured shims for “K 1”

and “K 2” and with small engagement bearing.
Note
♦ The large shim is inserted into the large engagement bearing,

with the hemispherical side of the shim facing downwards.
♦ The small shim goes under the small engagement bearing.
Therefore, insert shim first.
The shim and the small engagement bearing only fit in one posi‐
tion due to the 8 grooves.
– By turning, check that parts have been installed correctly and
that grooves are seated correctly.
– Turn back spindle of puller -T10373- .
Caution

installation.
– Install clutch with puller - T10373A- in gearbox, as shown in

diagram.

– If necessary, balance out gaps using -T10356/5- from assem‐
bly tool - T10356- , for example.
Note
– Press on clutch as far as it will go.
Note
One hand must be placed on the clutch when mounting. A slight

»rattling« will be felt. Rattling indicates that the clutch is being
pressed onto its press seat. This also enables detection of the
limit stop once the clutch has been seated correctly.
– Take hold of new retaining ring with retaining ring pliers, as

shown in the illustration.
• Mounting position: With the top gap of the circlip facing up‐
wards.
– Insert circlip -arrow-.
Note
If the retaining ring cannot be inserted, the clutch has not been
pressed in onto its limit stop.
– To bring the clutch to the service position, hold the spindle of

the puller - T10373A- firmly with one hand and pull the clutch
with the other hand in the opposite direction of the circlip in the
direction of rotation -arrow-.

Note
♦ By pressing on, the clutch sits at the bottom against the limit
stop on the input shaft. This is not the optimum position.
♦ Clutch should only be pulled up far enough for it to contact
retaining ring.
Note
Only turn by hand. In this way, clutch slides against retaining ring.
Do not use any other tool.
– Insert hub.
• byHub
Protected hasCopying
copyright. »large tooth«
for private -arrow-purposes,
or commercial and only fits
in part inwhole,
or in oneisposition.
not
• »Large
respect tooth«of has
to the correctness a mark
information in this at engine
document. end.by SEAT S.A.
Copyright
– Insert retaining ring -arrow- of hub.

• Joint of retaining ring must point towards »hub« of clutch.
– Turn clutch by hand. It should be possible to turn it without

difficulty.
Note
♦ If the clutch is difficult to turn or if the clutch lining is being

rubbed hard, remove clutch again ⇒ page 43 .
♦ Check installation position of shims -arrows-.
♦ The shims must be properly seated and undamaged
⇒ page 61 .
♦ A mathematical error could have been made. Check meas‐
urements again ⇒ page 48
♦ If no error has been made, the clutch may have been moved
out of position due to transport/assembly and a new clutch now
has to be installed. The position of the engagement bearings
must then be readjusted ⇒ page 48 .
– Remove two plugs and put breather caps -arrows-on.
WARNING



– Installing the breather hose:
♦ Leon 2009 ► ⇒ page 149
– Dispose of excess shims.
– After installation of gearbox, perform Complete reset by
means of Guided functions ⇒ Vehicle diagnostic tester.
3 Removing and installing oil seals at

clutch end
There are 2 radial oil seals in gearbox at clutch end. Both oil seals
can be renewed without gearbox being dismantled. If only oil
seals are renewed, there is not need to adjust clutch.

♦ Tube element - VW 415 A-
♦ Gasket ring extractor - T10420-

♦ Extractor tool -T20143/2-
Prior condition:
Dual clutch has been removed.
On gearboxes with date of manufacture 05.2011 ⇒ page 15 .
Gearbox date of manufacture from 06/2011 ⇒ page 41 .
Caution
If leaking, always check the dual clutch. Renew clutch if it is

oily.
– Lever out outer oil seal.
3. Removing and installing oil seals at clutch end 69

– Drive in outer, »new« oil seal with a plastic mallet until flush
with clutch housing.
• Shoulder of pipe section -VW 415 A- points upwards -arrow-.
WARNING
Only drive in oil seal until flush, in order to avoid closing off oil
drilling located behind it. Otherwise, bearing can no longer be
supplied with enough oil.
– Unscrew spindle of oil seal extractor - T10420- .
– Screw oil seal extractor - T10420- into »small«, inner oil seal.
Press puller when doing this.
Puller will become very tightly clamped when turning oil seal. You
can »feel« when oil seal starts to turn in its seat as well.
– Now screw in spindle.

– Pull out oil seal using spindle.
– Drive in new oil seal using thrust piece - T10421- (drive in until
thrust piece contacts stop).
Fitting depth of seal: 17.5 ± 0.2 mm.
– Install dual clutch ⇒ page 34 .
Note
In event of complaint due to “leaks”, it may be a tip to take a look

at the crankshaft of the engine.
Install gearbox ⇒ page 180 .

34 – Controls, housing
1 Selector lever: Emergency release
⇒ “1.1 Vehicles up to 02.2009”, page 71 .
⇒ “1.2 Vehicles from 03.2009 onwards”, page 72 .
Do not remove the handle ⇒ page 71 .
– Depress brake pedal or set handbrake.
In an emergency:
1.1 Vehicles up to 02.2009

Vehicles from 03.2009 onwards ⇒ page 72
The selector lever lock solenoid - N110- locks the selector lever
in position “P”. The selector lever can only be switched from the
“P” position when the ignition is turned on or the engine is running,
the brake pedal has been depressed and the button on the se‐
lector lever is pressed ⇒ page 89 .
In the event of malfunctions in the supply voltage to the selector
lever lock solenoid (discharged battery or defective fuse) or if the
solenoid is defective the selector lever cannot be shifted out of
position “P”. The vehicle cannot be moved, as the parking lock is
engaged.
In that case:
– check the fuses ⇒ Current flow diagrams, Electrical fault find‐
ing and Fitting locations.
– Check battery voltage ⇒ Rep. gr. 27 .
If fault finding has not been successful and selector lever can still
not be shifted from “P” the solenoid must be released manually.
However, if the selector lever returns to the position “P”, it will be
locked once again in position “P”.
Work sequence
– Hang out the trim -2 - and remove in the direction of the
-arrows-.
1. Selector lever: Emergency release 71

– Remove the basis with lamp -4- with the sleeve -3- via the
handle -2-.
– Remove central control ⇒ body- install inside; Rep. gr. 68 ;
interior
Note
For a better understanding of the figure, the switching activity is

shown without the handle for the selector lever and without the
housing of the switching operation. However, it is not necessary
to remove the selector lever handle to operate the manual release
mechanism.
– Unlock the magnet for the selector lever -A- with a screwdriver
through the hole on the housing of the switching activity.
– To do so press lever -B- inwards -arrow- with the screwdriver
and keep it in this position. In this way the electro-magnet will
release the selector lever.
Caution
The shift unit can only be renewed as a complete unit. This

means that if parts of the function unit of the selector mecha‐
nism are damaged it must be completely renewed.
– After unlocking the lever, press the button on the handle and
move the selector lever from position “P”.
Note
However, if the selector lever returns to position “P”, the electro-

magnet will, once again, lock the lever in position “P”. The sole‐
noid must be released once again.
1.2 Vehicles from 03.2009 onwards

Vehicles up to 02.2009 ⇒ page 71 .
The selector lever lock solenoid - N110- locks the selector lever
in position “P”. The selector lever can only be switched from the
“P” position when the ignition is turned on or the engine is running,
the brake pedal has been depressed and the button on the se‐
lector lever is pressed ⇒ page 89 .
In the event of malfunctions in the supply voltage to the selector
lever lock solenoid (discharged battery
Protected by copyright. or defective
Copying for private or fuse) or ifpurposes,
commercial the in part or in whole, is not
solenoid is defectivepermitted
the selector lever cannot be shifted out of
position “P”. The vehicle cannot be moved, as the parking lock is
engaged.
In that case:
– check the fuses ⇒ Current flow diagrams, Electrical fault find‐
ing and Fitting locations.
– Check battery voltage ⇒ Rep. gr. 27 .
72 Rep. gr.34 - Controls, housing

If fault finding has not been successful and selector lever can still
not be shifted from “P” the solenoid must be released manually.
However, if the selector lever returns to the position “P”, it will be
locked once again in position “P”.
Work sequence
– Hang out the trim -2 - and remove in the direction of the
-arrows-.
handle -2-.
– Apply pressure to the yellow plastic part.
Caution
The shift unit can only be renewed as a complete unit. This

means that if parts of the function unit of the selector mecha‐
nism are damaged it must be completely renewed.
– After unlocking the lever, press the button on the handle and
move the selector lever
Protected by from
copyright. position
Copying “P”.
Note
However, if the selector lever returns to position “P”, the electro-

magnet will, once again, lock the lever in position “P”. The sole‐
noid must be released once again.
1. Selector lever: Emergency release 73

2 Selector lever handle: assembly

overview
⇒ “2.1 Removing and installing selector lever handle”,
page 74 .
⇒ “2.2 Separate selector cuff from selector handle”, page 77 .
⇒ “2.3 Removing and installing selector lever display illumination
L101 ”, page 77 .
1 - Selector lever handle

❑ removing and installing
⇒ page 74
❑ Different versions: allo‐
cation ⇒ Electronic
Parts Catalog “ETKA”
2 - Trim ring
⇒ page 77
3 - Trim panel
⇒ page 74
4 - Selector lever boot
❑ Detaching from selector
lever handle
⇒ page 74
5 - Basis with selector lever
display illumination bulb -
L101-
❑ Remove and install:
Separate the cuff from
the handle ⇒ page 77
6 - Clip
❑ Secures selector lever
handle to selector lever
⇒ page 74
2.1 Removing and installing selector lever

handle

♦ Hose clip pliers - V.A.G 1275 A-
♦ Lever - 3409-
Removal:
– Shift selector lever to position “N”.
Note
The selector lever is removed together with the sleeve on the lev‐
er and the basis with illumination.
– Secure the interlock button in its extracted position with a

bracket as shown in the display.
– Hang-out the trim -2- using the lever - 3409- and remove in the
direction of the -arrow-.
2. Selector lever handle: assembly overview 75

handle -2-.
– Unplug electrical connection -1- from the selector lever display
illumination bulb.
– Open the bracket -arrow- and remove the handle -2- together
with the sleeve -3- and the basis with lamp -4- without con‐
tacting the interlocking button.
Installation
Note
♦ The interlocking button must be screwed out until its end po‐
sition so that the selector lever can be installed. Then the
handle must be secured with either a cable tie -arrow- or with
the assembly aid supplied together with the new handle.
♦ If, by mistake, the interlock button has not been secured, it
must not be pulled out of the selector lever handle by means
of mechanical tools. Position a compressed-air gun at the bot‐
tom of the handle and press the interlocking button out using
compressed air.
– Attach the handle across the entire scope of the selector lever
(the interlocking button points toward the driver).
• The handle must engage in the annular groove on the selector
lever.
– Remove the cable tie and the assembly sleeve. Then the ac‐
tuation of the button is applied in the vertical groove
Protected on theCopying for private or commercial purposes, in part or in whole, is not
by copyright.
selector lever. If necessary, using force, press the
permitted interlocking
button into the selector lever. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Plug-in the electrical connection -1- of the selector lever dis‐

play illumination bulb.
– Secure selector lever handle -2- onto selector lever with clamp
-arrow-. Use hose clip pliers - V.A.G 1275 A- for this purpose.
– Insert and lock the basis with lamp -4- for fixing the sleeve
-3- in the centre console.

2.2 Separate selector cuff from selector

handle
Removal:
– Removing the gear selector handle ⇒ page 74 .
– Tie together spring tips -1- on selector lever handle using cable
tie -3- as shown in illustration.
– Slide sleeve -2- of selector lever boot past retaining tabs on
spring tips -arrow-.
– Remove cable tie and detach sleeve with selector lever boot
from selector lever.
Installation
Installation is carried out in the reverse order, noting the following:
Fitting position of selector lever boot:
• The longer side of the retaining frame for the selector lever
boot faces the driver's side.
– Fit the selector lever handle ⇒ page 74 .
2.3 Removing and installing selector lever

display illumination - L101 -
Removal:
– Shift selector lever to position “N”.
– Switch off ignition and remove key.
– Unclip the cover frame for the gearshift lever on the centre
console and remove the cover frame upward -Arrows-
– Separate connection -1-.
– Release retaining springs -arrows-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove cover with lamp for gearshift lever
respectscale illumination
- L101- from cover for gearshift lever -1-
Installation
Installation is carried out in reverse order.
2. Selector lever handle: assembly overview 77

3 Selector mechanism in vehicles up to

02.2009
WARNING
Before working on vehicle while engine is running, shift selec‐

tor lever into position “P” and apply handbrake.
Gear selection mechanism from 03.2009 ⇒ page 84 .
3.1 Overview of selector mechanism up to 02.2009
1 - Selector cover with knob

❑ Do not remove the han‐
dle unnecessarily. Only
unclip cover for emer‐
gency release
⇒ page 71 .
❑ Before removing knob,
pull lock button out past
its pressure point. Se‐
cure locking button with
a cable tie or appropri‐
ate wire against being
pressed in. This will pre‐
vent lock button from
being accidentally
pressed into the knob.
⇒ page 79
2 - Selector lever and gear se‐
lector mechanism
❑ With selector lever lock
solenoid - N110-
❑ Brief instructions for re‐
moving and installing:
– Remove object tray over
tunnel:
– Remove Bowden cable

from gearbox
⇒ page 79 .
– If necessary, disconnect
or remove partsbyofcopyright.
Protected ⇒ ex‐Copying for private or commercial purposes, in part or in whole, is not
haust system; Rep.
permitted unless gr. by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
authorised
26 . respect to the correctness of information in this document. Copyright by SEAT S.A.
– Remove heat shield be‐

neath vehicle.
– Adjust selector lever cable after installing ⇒ page 90 .
3 - Bolt with spring

❑ 3 Nm
4 - Bolt
❑ Removing ⇒ page 79 .
❑ Cable must not be greased

5 - Locking plate
❑ Always replace following removal
6 - Nut
❑ 4x
❑ 9 Nm.
7 - Protective housing of the selector
❑ With seal
8 - Selector lever cable
❑ Cable must not be greased
❑ removing and installing ⇒ page 79
❑ Checking and adjusting ⇒ page 90
9 - Retainer washer
10 - Hexagon flange nut
❑ 4x
❑ M6 - 8 Nm
❑ M8 - 20 Nm
3.2 Removing and installing selector

Protected lever
cable up to 02.2009
Selector lever and selector mechanism with gear selector cable:

removing and installing, from contruction year 03/2009
⇒ page 85 .
♦ Pressing-off lever - 80 - 200-
3. Selector mechanism in vehicles up to 02.2009 79

3.2.1 Removal:
– Put the gear selector lever into position “S”.
– Switch ignition OFF.
– Remove the selector lever control cable -2- from the lever of
the selection shaft using the removal lever - 80 - 200- .
– Remove the circlip -1- for the selector lever control cable and
leave the selector lever control cable in its assembly position.
Engines 1.4 l - 110 kW TSI and 1.4 l - 132 kW TSI
– Remove the front section (catalytic converter) of the exhaust
system ⇒ 4-cylinder injection engine (1.4 l, 4 direct-injection
valves, turbocharger and rotary piston compressor); Rep. gr.
26 ; Exhaust system
Engine 1.6 l - 77 kW SRE
– Remove the front section of the exhaust system ⇒ 4-cylinder
injection engine (1.6 l, 4 V, chain transfer); Rep. gr. 26 ; Ex‐
haust system
– Remove the front section of the exhaust system on the un‐
dercarriage.
– Loosen the nuts on the inside -arrow- of the left and right un‐
dercarriage of the vehicle.
– Unfasten bolted joints of clamp -2- and disconnect exhaust
system.
– Loosen clips -arrows- and detach heat
permitted shield
unless towards
authorised rear.
by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

– Remove bolts -arrows- and detach cover.

– Slide the cover and the protective sheath over the selector
lever cable forward. The protective sheath must not be dam‐
aged.
– Remove bolts -arrows-.
Caution
Electric components on retaining frame can be damaged by

electrostatic discharge.
♦ Do not touch printed circuit -B- with bare hands.

Note
The printed circuit can only be renewed together with the shift unit!
– Unclip retaining tabs on both sides and detach detent plate

-A- from shift unit.
– Pull locking plate -1- securing selector lever cable to shift unit
downwards and remove.
– Pull plastic retaining spring -2- forwards slightly and press pin
-3- upwards only as far as necessary -arrow-.
Note
♦ This operation may only be carried out when the selector lever
is in position “S”.
♦ Make sure the bolt does not come out completely.
– Pull selector lever cable -4- out of shift unit.
Note
Do not bend or kink the selector lever cable.
3.2.2 Installation
Installation is carried out in the reverse order, noting the following:

Note
♦ Renew locking plate for selector lever cable.

♦ Check protective sleeve for damage. The protective sleeve
can only be renewed together with the selector lever cable.
♦ Check that the protective sleeve is seated correctly and not
twisted.
• Tightening torque ⇒ page 78 .

– Insert selector lever cable with protective sleeve into cover,
taking care not to damage protective sleeve.
– Insert the end of the selector lever cable -4- into the joint of the
selector lever.
– Press pin -3- downwards -arrow- and check that plastic re‐
taining spring -2- has engaged
Protected in Copying
by copyright. pin. for private or commercial purposes, in part or in whole, is not
– Insert new locking plate -1-tofor
respect selectoroflever
the correctness cable.
information in this document. Copyright by SEAT S.A.
• Installation position: angled end must point towards shift unit.
Caution
Electric components on retaining frame can be damaged by

electrostatic discharge.
♦ Do not touch printed circuit -B- with bare hands.
– Clip in detent plate -A- and tighten bolts -arrows-.
– Hand-tighten cover (with glued-on seal) to selector mecha‐

nism -arrows-, making sure that seal is seated correctly.
– Fit the protective sheath of the selector lever cable on the cov‐
er.

– Carefully push selector lever cable -2- onto selector shaft lever
on gearbox and secure with locking plate -1- to cable support
bracket.
– Change the gear selector lever from position “S” to “P”.
• Shift unit and selector lever cable must move freely; if neces‐
sary renew selector lever cable.
– Put the gear selector lever into position “P”.
– Tighten bolts -arrows- for cover (bottom).

– Install heat shield ⇒ Rep. gr. 66 .
– Install the front section (catalytic converter) of the exhaust
system ⇒ 4-cylinder injection engine (1.4 l, 4 direct-injection
valves, turbo and rotary piston compressor); Rep. gr. 26 ; Ex‐
haust system and adapt without tensioning.
– Install the front section of the exhaust system ⇒ 4-cylinder
injection engine (1.6 l. 4 V, chain transfer); Rep. gr. 26 ; Ex‐
haust system and adapt without tensions.
– Adjust selector lever cable ⇒ page 90 .
– Gear mechanism: verification ⇒ page 89 .

4 Selector mechanism from 03.2009

onwards
WARNING
Before working on vehicle while engine is running, shift selec‐

tor lever into position “P” and apply handbrake.
Selector mechanism; vehicles to 02/2009 ⇒ page 78 .
4.1 Overview of selector mechanism in vehicles from 03.2009 onwards
1 - Selector cover with knob

❑ Do not remove the han‐
dle unnecessarily. Only
unclip cover for emer‐
gency release
⇒ page 71 .
❑ Before removing knob,
pull lock button out past
its pressure point. Se‐
cure locking button with
a cable tie or appropri‐
ate wire against being
pressed in. This will pre‐
vent lock button from
being accidentally
pressed into the knob.
⇒ page 74
2 - Selector lever and gear se‐
lection mechanism with gear
selector cable
❑ With selector lever lock
solenoid - N110-
❑ Do not lubricate the gear
selector cable
⇒ page 85
❑ Checking and adjusting
⇒ page 90
3 - Bolt
❑ 8 Nm.
4 - Hexagon flange nut
❑ 4x
❑ M6 - 8 Nm
❑ M8 - 20 Nm permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
5 - Protective housing of the selector
6 - Locking plate

4.2 Selector lever and selector mechanism

with gear selector cable: removing and
installing, from contruction year 03/2009
⇒ “4.2.1 Removing and installing selector mechanism with selec‐
tor housing”, page 85
⇒ “4.2.2 Removing and installing selector mechanism without se‐
lector housing”, page 87
4.2.1 Removing and installing selector mech‐

anism with selector housing
Brief description
Selector mechanism and selector lever cable are not allowed to
be separated from one another. Both are removed together with
the selector housing.
In the interior the centre console is to be removed.
The heat shield beneath the vehicle must be removed.
The selector mechanism with selector lever cable can be re‐
moved and installed separately without removing and installing
the selector housing ⇒ page 87 .
Note
Following installation of selector mechanism, selector lever cable

must be checked for ease of movement and be adjusted.
Removal:
– Remove selector lever knobProtected
⇒ page 74 . Copying for private or commercial purposes, in part or in whole, is not
by copyright.
– Remove centre console ⇒ General body
respect to the repairs,
correctness interior; Rep.
of information in this document. Copyright by SEAT S.A.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Separate electrical connector from selector mechanism to ve‐
hicle wiring harness.
– Remove the air filter assembly:
♦ Petrol engine ⇒ Rep. gr. 24 ; Air filter; Removing and installing
air filter housing .
♦ Diesel engine ⇒ Rep. gr. 23 ; Air filter; Removing and installing
4. Selector mechanism from 03.2009 onwards 85

– Remove the securing disc.

Use pliers to remove the securing clip on the cable support brack‐
et. Do not use a sharp-edged lever, as the selector lever cable
could become damaged.
Securing clips for selector lever cable must always be renewed.
– Remove cable from ball head.
– Remove heat shield for middle tunnel beneath selector mech‐
anism ⇒ General body repairs, exterior; Rep. gr. 66 ; Under‐
body cladding; Assembly overview - underbody cladding .
Note
The assistance of a second mechanic is required to detach the

selector mechanism from under the vehicle.
– Remove nuts -arrows- inside vehicle.

– If fitted, remove bracket -A-.
– Remove selector mechanism -B- together with selector lever
cable and selector housing downwards.
Installation
Installation is carried out in the reverse order.
Note
♦ Do not bend or twist the selector lever cable.

♦ Do not grease selector lever cable.
♦ Tightening torques ⇒ page 84

– Install heat shield for middle tunnel beneath selector mecha‐

nism ⇒ General body repairs, exterior; Rep. gr. 66 ; Under‐
body cladding; Assembly overview - underbody cladding .
– Install centre console ⇒ General body repairs, interior; Rep.
sole .
– Install selector lever handle ⇒ page 74 .
– Check selector mechanism ⇒ page 90 .
– Install air filter housing:

4.2.2 Removing and installing selector mech‐

anism without selector housing
Brief description
Selector mechanism and selector lever cable are not allowed to
be separated from one another. They can only be removed to‐
gether.
In the interior the centre console is to be removed.
A cord must be attached to the Bowden cable before it is removed.
The cord is needed to guide the Bowden cable between the tunnel
and the heat shield.
The selector mechanism with selector lever cable can be re‐
moved and installed together with the selector housing
⇒ page 85 .
Removal: permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Remove selector lever knob ⇒ page 74 .
– Remove centre console ⇒ General body repairs, interior; Rep.
sole .
– Separate electrical connector from selector mechanism to ve‐
hicle wiring harness.
– Remove air filter housing.
– Remove the securing disc.

Use pliers to remove the securing clip on the cable support brack‐
et. Do not use a sharp-edged lever, as the selector lever cable
could become damaged.
Securing clips for selector lever cable must always be renewed.
– Then a long cord must be attached to the end of the Bowden
cable. The cord is needed to guide the Bowden cable between
the tunnel and heat shield during installation.
– Remove 4 bolts.
4. Selector mechanism from 03.2009 onwards 87

– Carefully pull selector mechanism with Bowden cable out of

the centre tunnel. Ensure that the cord remains accessible
from the engine compartment after being pulled by the Bow‐
den cable.
– Remove cord from the cable.
Installation
Installation is carried out in the reverse sequence; note the fol‐
lowing:
A second mechanic is required to thread the cable from the pas‐
senger compartment to the engine compartment.
Note
♦ Do not bend or twist the selector lever cable.

♦ Do not grease selector lever cable.
♦ Torque settings ⇒ page 84 .
– Attach Bowden cable to cord which was drawn into the pas‐
senger compartment during removal.
– Carefully guide selector mechanism with Bowden cable
through opening in centre tunnel.
– Have the second mechanic pull cord with Bowden cable
through tunnel from engine compartment until it can be at‐
tached to support bracket.
– Remove cord from the cable.
– Secure selector mechanism to selector housing using 4 bolts.

– Install centre console ⇒ General body repairs, interior; Rep.
sole .
– Install selector lever handle ⇒ page 74 .
– Check selector mechanism ⇒ page 90 .
– Install air filter housing:

5 Checking selector mechanism

Selector mechanism: overview, vehicles from 03.2009 onwards
⇒ page 84 .
Selector mechanism; vehicles to 02/2009 ⇒ page 78 .
Selector lever control cable: checking and adjusting
⇒ page 90 .
⇒ “5.1 Selector lever in P position and ignition switched on”, page
89
⇒ “5.2 Selector lever in N position and ignition switched on”, page
89
⇒ “5.3 Selector lever in position Tiptronic ”, page 90
⇒ “5.4 Ignition and light switched on”, page 90
⇒ “5.5 Selector lever position display”, page 90
⇒ “5.6 Selector lever control cable: checking and adjusting”, page
90
⇒ “5.7 Checking function of ignition key removal lock”,
page 92
It must be possible to start the engine if the selector lever is lo‐
cated in “R”, “D”, “S” or the position Tiptronic.
In vehicles with right-hand drive and selector level in position “P”
or “N”, it must be possible to start the engine if the button of the
selector lever is not pressed.
When selector lever is shifted to position “N” at speeds above 5
km/h, solenoid for selector lever lock must not engage and block
selector lever. Selector lever can be shifted into a driving range.
When travelling at speeds below 5 km/h (almost stationary) and
shifting into selector lever position “N”, solenoid for selector lever
lock should only engage after about 1 second. Selector lever can‐
not be shifted out of “N” position until brake pedal is depressed.
5.1 Selector lever in “P” position and ignition

switched on
• Brake pedal is not depressed:
Selector lever is locked and cannot be shifted out of “P” position
with the lock button pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to select a gear. Slowly shift selector lever from “P” through
to “S”, checking whether selector lever position in dash panel in‐
sert corresponds to actual selector lever position.
5.2 Selector lever in “N” position and ignition

switched on
• Brake pedal is not depressed:
Selector
Protectedlever is locked
by copyright. Copyingand cannot
for private be shifted
or commercial out
purposes, of “N”
in part position
or in whole, is not
with therespect
locktobutton pressed. Solenoid for selector lever lock
the correctness of information in this document. Copyright by SEAT S.A.
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to select a gear.
5. Checking selector mechanism 89

5.3 Selector lever in position “Tiptronic”

– Shift selector lever into tiptronic gate.
Symbols must change from “P R N D S” to “7 6 5 4 3 2 1”.
5.4 Ignition and light switched on

The respective symbol in the shift mechanism cover lights up.
5.5 Selector lever position display

Simultaneous illumination of all selector lever position display
segments indicates gearbox emergency running mode.
5.6 Selector lever control cable: checking

and adjusting
Brief description
Selector lever cable must be removed from gearbox so that its
ease of movement can be checked. Put removed end down so it
does not rub against anything.
The selector lever must be moved and then the cable must be
reattached to the gearbox.
Then the selector lever cable must be adjusted.
Do not lubricate the cable!
Adjust the selector lever cable whenever:
♦ The selector lever cable has been removed from the gearbox.
♦ The engine and/or gearbox has been removed and installed.
♦ Parts of the assembly mounting have been removed and in‐
stalled.
♦ The cable itself or the selector mechanism has been removed
and installed.
♦ The position of the engine and gearbox is shifted, for example
to install it free of tension.
♦ Torque wrench - V.A.G 1331-
Checking
– Shift selector lever into position »P«.
– Remove cable from lever on gearbox.
– Move selector lever repeatedly from »P« to »S« and back to
»P«.
• Selector lever must move easily.

– Install the selector cable with the adjustment screw previously

unscrewed.
If securing clip was removed, always install a »new« securing clip.
– Finally adjust selector lever cable.
Set
– Move selector lever in vehicle to “P” position.
Adjuster screw -arrow- must be »loosened«.

– Shift lever on gearbox to position “P”.
The lever must be pressed completely to the right-hand side of

the vehicle in the direction of the cable support bracket for the
selector lever cable.
In the illustration the gearbox is shown viewed from the »rear«,
-P- is located in the direction of the cable support bracket.

– Install cable with previously loosened adjuster screw -arrow-

and new securing clip.
WARNING
The parking lock must be engaged.
– To do this, turn both front wheels simultaneously »under the

car« in the same direction until the parking lock can be heard
to engage.
• The parking lock is engaged when both front wheels cannot
be turned in the same direction at the same time.
– Gently push knob of selector lever forwards and backwards
but under no circumstances must you shift out of “P”. by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
In this way the inner cable of the Bowden cable finds itrespect
optimal
position.
– Tighten adjusting screw -arrow- to 13 Nm.

This completes the adjustment.
5.7 Checking function of ignition key remov‐

al lock
Vehicles up to 02.2009 ⇒ page 71 .
Vehicles from 03.2009 onwards ⇒ page 72
– Turn the ignition key slightly clockwise to the “ignition on” po‐
sition.
– Press and hold brake pedal.
• Switching from position “P” of the selector lever must be pos‐
sible with pressed interlock button on the selector lever without
tick.
• It should not be possible to remove the ignition key when the
selector lever is in any position other than “P”.
– Shift selector lever to position “P”.
– Remove the ignition key.
• It should only be possible to remove ignition key in selector
lever position “P”.
• The selector lever cannot be moved from “P” when the inter‐
lock button and the brake pedal is depressed.
If the ignition key removal lock does not function as described:
♦ Selector lever control cable: checking and adjusting
⇒ page 90 .

♦ Check the vehicle by selecting the function “Guided Fault

Finding” in the vehicle diagnosis, measuring and information
system .

6 Safety note on mechatronic unit for dual clutch gearbox - J743-
DANGER!
Do not work on pressure accumulator. The accumulator is un‐

der pressure and is not allowed to be opened.

7 Overview - mechatronic unit
1 - Bolt
moval
❑ M8x35
❑ 10 Nm.
Note
♦ Do not unscrew bolts if you are

not sure whether it is necessary
to do so.
♦ Be sure to read the removal de‐
scriptions first.
2 - Bolt
moval
❑ M8x90
❑ 10 Nm.
3 - mechatronic system for au‐
tomatic DSG gearbox - J743-
Note
♦ Observe the following when in‐

stalling a new mechatronic unit:
♦ After unpacking a new mecha‐
tronic unit, do not discard the
packaging or the red cap on the
breather pipe. These will be nee‐
ded for returning the old mecha‐
tronic unit.
♦ A »new« mechatronic unit is cor‐
rectly filled with oil. Do not drain
or top up oil.
♦ Before installation of the mecha‐
tronic unit the remaining oil must
be extracted from the gearbox
⇒ page 135 .
7. Overview - mechatronic unit 95

– When working on mechatronic unit, please remove cap from

breather and seal with a suitable plug so that no oil can es‐
cape.
WARNING

If the hydraulic fluid should drain out, the oil level can be ad‐
justed properly only through an oil change. It is not possible to
carry out a filling level check.

Removing and installing the breather hose:
♦ Leon 2009 ► ⇒ page 149

8 Removing mechatronic unit for dual

clutch gearbox - J743- ; gearbox is
installed
♦ Removal lever - T10407-
♦ Diesel extractor - VAS 5226-
♦ Vehicle diagnosis tester

Brief description
In order to remove the mechatronic unit, sufficient space must be
available in front of the gearbox. Depending on the vehicle, parts
must be removed which do not have anything to do directly with
the gearbox. For example, the air filter housing, if present, charge
air lines or coolant lines. In the Ibiza for example you must remove
the control unit for the radiator fan - J293- together with the brack‐
et.
Any retainers fitted to the bolts in the cover of the mechatronic
unit must be removed.
Tester moves all gear actuators »into neutral position«.
In this position, insert assembly lever - T10407- between clutch
lever and gearbox housing. This makes it possible to remove load
from plungers of mechatronic unit so that they may be removed
by hand from cups of engaging levers.
Mechatronic unit can be removed and inserted. When installing,
make sure clutch plunger is correctly seated in cup of engaging
levers.
Therefore, please follow description below step by step.
8. Removing mechatronic unit for dual clutch gearbox J743 ; gearbox is installed 97
Note
♦ The clutch is self-adjusting. Shocks can have an effect on this

adjusting device. Even if the mechatronic unit has been re‐
moved, the »sudden removal« of the assembly lever - T10407-
from under the engaging levers can have a negative effect on
the adjusting mechanism.
♦ In order to remove the mechatronic unit, sufficient space must
be available in front of the gearbox. In some vehicles, parts
must be removed which do not have anything to do directly
with the gearbox. Remove any charge air lines or coolant lines
that may be present.
♦ Any retainers fitted to the bolts in the cover of the mechatronic
unit are also removed.
♦ After unpacking a new mechatronic unit, do not discard the
packaging or the red cap on the breather pipe. These will be
needed for returning the old mechatronic unit.
♦ A »new« mechatronic unit is correctly filled with oil. Do not
drain or top up oil.
♦ If a mechatronic unit is returned it is essential that the terms
for returns are complied with.
Mechatronic unit remains filled with oil.
8.1 Mechatronics for dual clutch gearbox -

J743- removal; gearbox installed, Ibiza
2008 ►, Ibiza ST 2010 ►
Removal:
Caution
When the mechatronic unit for dual clutch gearbox - J743- is
removed or the gearbox oil has not been filled, do not start the
engine or tow the vehicle.
– Raise vehicle. All 4 supports of lifting platform must be at same

height.
– Connecting the Vehicle diagnostic, testing and information
system
– Select Guided functions .
– From the “7-speed dual clutch gearbox”, select the basic
position, removal position .
Caution

♦ Observe the measures to be adopted when disconnecting
the battery ⇒ Rep. gr. 27 .

– Raise the vehicle

– Place the lock carrier plate into service position ⇒ Bodywork,
exterior fitting work; Rep. gr. 50 .
– Pull the electrical connectors -2-, -3- and -4- out of their re‐
tainers.
– Dismantle the retainers and remove them.
– Remove nuts -arrows- and push bracket -1- to one side.
Caution
Risk of damage to gearbox components.

♦ Never touch contacts in gearbox connector with your
hands. Electrostatic discharge could cause irreparable
damage to the control unit and, consequently, the mecha‐
tronic unit.
– Touch a suitable earthed object with your hand (without

gloves) to discharge any static electricity.
– To unlock and remove the plug connection on the catch draw
out the plug connection of mechatronics.
– Remove oil drain plug -arrow- from gearbox.
– Drain gear oil.

– Install oil drain plug.
Note
Depending on the vehicle it may be necessary to remove»the«

control unit for the radiator fan - J293- together with the bracket.

– Pull off the breather cap and close using clean plugs from en‐
gine bung set - VAS 6122- to achieve an oil-tight seal.
WARNING
With several gearboxes, the breather Protected

cap onbythe mechatronic
unit is destroyed during removal andpermitted
must be renewed.


– Removing the breather hose ⇒ page 148 .

– Using a screwdriver, carefully unclip gearbox input speed
sender 3 - G641- from housing in direction of arrow.
The next step is »difficult«:

Now press both engaging levers of dual clutch »away« from

plungers of mechatronic unit. Otherwise, levers will jam mecha‐
tronic unit at plungers and prevent mechatronic unit from being
removed.
– Please read through this description all the way to the end first.
This should help you to perform the following steps »correct‐
ly«.
Both levers must now be carefully pressed away from the plung‐
ers.
– First take a look at -reddish-brown- engaging lever in this pic‐
ture.
– Insert assembly lever - T10407- to the right.

– Far enough until groove lines up with housing rib.
No further.
– Assembly lever - T10407- should make contact with gearbox
housing with its entire »rear face«.
Caution
– Apply a bit of force to tip of lever when turning.

This stops lever from slipping out when turning.
Turn assembly lever - T10407- anticlockwise. In this way, engag‐

ing levers are pressed away from plungers.

Do not take out assembly lever - T10407- . He remains between

the clutch pedal and the gearbox housing during the entire as‐
sembly.
– If necessary, press assembly lever - T10407- against gearbox
using a screwdriver.
Note
The assembly lever - T10407- must remain inserted between

clutch lever and gearbox housing after removing the mechatron‐
ics. Removing the lever could have a negative effect on the clutch
adjustment.

– Unscrew bolts of mechatronic unit for dual clutch gearbox -

J743- »in diagonal sequence«.
Note
Mechatronic unit is delivered for reconditioning with its oil in.
– Remove bolts -B- in diagonal sequence.

– Unscrew bolts -A-.
– Pull off mechatronic unit from gearbox.
»There are 4 long and 3 short bolts.«
Do not remove more than 7 bolts!
– For this purpose, take good care as to which screws you re‐
move. Do not undo screws from the cover.
The gearbox is shown here again from the side to make this sit‐
uation clearer.
The mechatronic unit must be removed. The cover does not have
to be removed.
Therefore, do not remove more than 7 bolts!
– Detach mechatronic unit.
– Make sure no oil runs out of breather.
WARNING
If mechatronic unit »jams« and cannot be removed:
In some cases it may not be possible to remove the mechatronic

unit. In this case, the gear actuator is »caught« at the »top left«
of the gearbox housing.
– First reposition mechatronic unit on gearbox housing and se‐
cure it with one bolt.
– Move mechatronic unit into »removal position« by hand
⇒ page 132 .
Caution
If a new Mechatronic is supplied for a replacement, the tappets

are in an extracted position ex-factory. In some cases it may
be difficult to pull them out when attempting to set. In such ca‐
ses, you have to lever it out lightly using a screwdriver.
Note
The remaining oil must be extracted from the gearbox before the
mechatronic unit is fitted.

– Extract the remaining oil from the gearbox with the oil extrac‐
tion unit - VAS 5226- .
Installing mechatronic ⇒ page 134 .
8.2 Mechatronics for dual clutch gearbox -

J743- removal; gearbox installed, Altea
2009 ►, Altea XL 2009 ►, Leon 2009 ►
Overview - mechatronic unit ⇒ page 95 .
Mechatronic unit for dual clutch gearbox - J743- Removing; gear‐
box is installed ⇒ page 97 .
Moving mechatronic unit for dual clutch gearbox - J743- into »re‐
moval position« by hand ⇒ page 132 .
Install mechatronic unit for dual clutch gearbox - J743-
⇒ page 134 .
Removal:
height.
– Put the gear selector lever into position »P«.
system
Caution


– Remove noise insulation ⇒ Rep. gr. 50 ; Noise insulation -
exploded view .
Line which are in the way during installation and removal work are
located in front of the Mechatronic These may be coolant or air
intake lines depending on the engine.
– Remove the hose of the charge air cooler -items 1 and 2-.
WARNING
Hot steam/hot coolant can escape - risk of scalding.

♦ The cooling system is under pressure when the engine is
hot.
♦ Cover filler cap on expansion tank with a cloth and open
carefully to release pressure.
– If required: drain coolant ⇒ Power unit; Rep. gr. 19 ; Map-

controlled engine cooling .
– Unplug electrical
permitted connector
unless authorised by SEAT-2-
S.A.on
SEATradiator outlet
S.A does not coolant
guarantee tem‐
or accept any liability with
perature sender - G83-
respect to the . of information in this document. Copyright by SEAT S.A.
correctness
– Lift retaining clip and remove coolant hose -1- from radiator.
Continued for 1.8 TFSI engines only

– Remove charge air cooling pipe together with hose. For this
purpose disconnect the electrical connector for the intake
manifold pressure sensor - G71 - -Arrow- and place at side,
disconnect flange shaft -3- and pull out mounting bolts
-1 and 4-.


Continuation for all vehicles

– Remove all retainers and brackets from front of gearbox.
– Drain gear oil.

WARNING

unitProtected
is destroyed during
by copyright. Copying removal
for private or and mustpurposes,
commercial be renewed.
in part or in whole, is not
It is notrespect
possible to checkof the
to the correctness fill level
information in thisof the hydraulic
document. Copyright byfluid
SEAT sec‐
S.A.
The mechatronic unit must be renewed if oil escapes.



removed.

– Please first read this operating instruction completely. This will

help you to perform the following steps correctly.
ers.
– First note the -red- engaging lever in the illustration.
– Insert the assembly lever - T10407 - to the right of this.

No further.
Caution
– Apply a little force to the tip of the lever when turning.


Do not take out assembly lever - T10407- . It must remain inserted

between clutch lever and gearbox housing for the entire process.

Note
Do not take out assembly lever - T10407 - . Pulling it out may have
a negative influence on the clutch adjustment.

uation clearer.
The mechatronic unit must be removed. The cover does not have
to be removed.
Therefore, do not remove more than 7 bolts!
– Make sure that oil does not run out of the ventilation.


– First fit the mechatronic unit in the gearbox housing again and
secure with a bolt.
– The mechatronic unit must be moved to the »position for re‐
moval« by hand ⇒ page 132 .
Caution

bepermitted
difficult tocopyright.
Protected by pull them out
Copying for when
private orattempting to set.
commercial purposes, In orsuch
in part ca‐is not
in whole,
ses, you have tocorrectness

lever it ofout lightlyinusing a screwdriver.
respect to the information this document. Copyright by SEAT S.A.
Note
Installing mechatronic ⇒ page 134 .
8.3 Removing mechatronic unit for dual

clutch gearbox - J743- ; gearbox is in‐
stalled, Toledo 2013 ►
Overview - mechatronic unit ⇒ page 95 .
Mechatronic unit for dual clutch gearbox - J743- Removing; gear‐
box is installed ⇒ page 97 .
Moving mechatronic unit for dual clutch gearbox - J743- into »re‐
moval position« by hand ⇒ page 132 .
Install mechatronic unit for dual clutch gearbox - J743-
⇒ page 134 .
Removal:
height.
system
Caution

♦ Observe the measures to tobetheadopted
respect correctness when disconnecting
of information in this document. Copyright by SEAT S.A.
– Disconnect battery ⇒ Electrical installation; Rep. gr. 27 .

– Open filler cap on expansion tank.

WARNING
Hot steam/hot coolant can escape - risk of scalding.

♦ The cooling system is under pressure when the engine is
hot.
♦ Cover filler cap on expansion tank with a cloth and open
carefully to release pressure.

exploded view .
– Unplug electrical connector -2- on radiator outlet coolant tem‐
perature sender - G83 - .
– Detach coolant hose (bottom) -1- from radiator (lift retaining
clip).
– Remove radiator cowl ⇒ Engine, permitted
mechanics; Rep. gr.
unless authorised 19S.A.
by SEAT . SEAT S.A does not guarantee or accept any liability with
Note
Depending on the vehicle it may be necessary to remove»the«

control unit for the radiator fan - J293- together with the bracket.


– Drain gear oil.


WARNING

The mechatronic unit must be renewed if oil escapes.



removed.
– Please first read this operating instruction completely. This will
help you to perform the following steps correctly.
ers.
– First note the -red- engaging lever in the illustration.
– Insert the assembly lever - T10407 - to the right of this.

No further.
Caution
– Apply a little force to the tip of the lever when turning.



Do not take out assembly leverrespect
- T10407 - . It must
to the correctness remainininserted
of information this document. Copyright by SEAT S.A.
between clutch lever and gearbox housing for the entire process.
Note
Do not take out assembly lever - T10407 - . Pulling it out may have
a negative influence on the clutch adjustment.


Note

– Pull off mechatronic unit from gearbox.
uation clearer. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Make sure no oil runs out of breather.

– First re-install the mechatronic of the gearbox housing and
secure using a screw.
– The mechatronic unit must be moved to the »position for re‐
moval« by hand ⇒ page 132 .
Caution

Note

Install mechatronic unit ⇒ page 134 .
9 Moving mechatronic unit for dual clutch gearbox - J743- into »removal
position« by hand
Sometimes, the mechatronic unit cannot be removed. In this
case, the gear actuator is »caught« at the »top left« of the gearbox
housing -arrow-.
The »sticking« gear actuator -arrow- can be pressed by hand into

its »removal position«. To do this, push a selector fork behind the
parking lock cover.
Procedure:
– First reposition mechatronic unit on gearbox housing and se‐
cure it with one bolt.
– Shift selector lever into position “P”. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Remove the retaining washers -arrow-.

– Securing clips for selector lever cable must always be re‐
newed.

– To do this, press lever by hand as far as it will go in direction
of cable support bracket.
– Remove lever of selector shaft.

– Unbolt cover.
WARNING
The mechatronic unit will not be »stuck« after the next step.
This means that they may fall down. If it has not already been
done, secure mechatronic unit on gearbox with one bolt to pre‐
vent it from falling down.
– Working through opening, push selector fork to side.

(Press to left in direction of travel.)
This presses back the »sticking gear« actuator and the mecha‐
tronic unit can then be removed.
– Add gear oil after completing work on mechatronic unit
⇒ page 194 .
9. Moving mechatronic unit for dual clutch gearbox J743 into »removal position« by hand 133
10 Installing mechatronic unit for dual

clutch gearbox - J743-
♦ Guide pin - T10406-
♦ Diesel extractor - VAS 5226-
Prior condition:
The assembly lever - T10407- is inserted between clutch lever
and gearbox housing..
Note
♦ Observe the following when installing a new mechatronic unit:

♦ After unpacking a new mechatronic unit, do not discard the
packaging or the red cap on the breather pipe. These will be
needed for returning the old mechatronic unit.
♦ A »new« mechatronic unit is correctly filled with oil. Do not
drain or top up oil.
♦ If a mechatronic unit is returned it is essential that the terms
for returns are complied with.
WARNING
Before installation oftothe mechatronic unit,inensure thatCopyright

there by is SEAT S.A.
respect the correctness of information this document.
no more oil in the gearbox.

– Otherwise oil still in the gearbox is to be extracted with the oil

extraction unit - VAS 5226- .
Caution

Installation
– All selector forks are positioned in »neutral« position.
Note
Make sure that all selector forks are located in -N-, »in the middle«, and therefore that the gearbox is in neutral.
10. Installing mechatronic unit for dual clutch gearbox J743 135
– Each of the 4 selector forks must be checked by hand for this

purpose.
Each selector fork has 3 possible positions: »gear engaged -
neutral position - gear engaged«.
– Move each fork once into each position in succession. Then
all gears must be pulled out and the switching forks must be
moved to the »centre position«.
Note
»Neutral, neutral, neutral«, or gearbox will not function!
Turn gear slightly for assistance. This makes it »easier« to shift

the forks.
– Clean sealing surface where mechatronic unit will make con‐
tact later on.
Oil residues on sealing surface will later result in a misdiagnosis
of »leaking«.

– Screw in guide pin - T10406- until finger-tight.
Make sure that all gear actuators project by 25 millimetres -a-.
Caution
When levering the plungers out of the mechatronic unit, make

sure that you do not brace yourself on the sensors.
– Clean sealing surface of mechatronic unit.
– It is essential to watch out for seal on mechatronic unit.

Seal must engage all round.
– Pay attention to sender. Clip must not be damaged.
– Put on mechatronic unit.
– When gripping and putting on, make sure selector forks are
not inadvertently pressed out of their position.
– Also observe engaging levers and plungers on mechatronic
unit.
– Fit mechatronic unit.

– Screw in 7 new bolts and tighten until finger-tight.
– Remove guide pins - T10406 - again.
– Ensure that the lifter runs duly into the intended hollows of the
engaging levers.
– Take out the lifter with the hand so far, until it sits in the mould.
Plungers can be moved into position with a hook bent from a piece
of welding wire.
– Control the position of the plunger again.

Plungers that are not seated correctly will damage mechatronic

unit.
– Tighten mechatronic unit diagonally to 10 Nm.
– Turn assembly lever - T10407- clockwise and remove it.
– Install gearbox input speed sender 3 - G641- .

– Pay attention to sender. Clip must not be damaged.
• Sender lug must be fully and firmly in contact with gearbox
housing. If sender is »loose« because the clip is broken, renew
mechatronic unit.
– Remove plug and put on breather cap.
WARNING


– Installing the breather hose ⇒ page 148 .

– Put on connector of mechatronic unit.
– Install all front brackets of the gearbox.

Fill up gear oil ⇒ page 194 .
Continued for Ibiza model only
– Fit the lock carrier plate: ⇒ Bodywork, exterior fitting work;
Rep. gr. 50 .

Continued for Toledo model only

– Install radiator cowl ⇒ Engine, mechanics; Rep. gr. 19 .
Continued for 1.8 TFSI engines only

– Mount the charge air cooling pipe together with hose.
Continuation for all vehicles

– Fit coolant hose or air lines if necessary.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and connecting battery .
– If necessary: fill up coolant ⇒ Engine ; Rep. gr. 19 ; coolant:
drain and fill up .
– Install noise insulation⇒ Rep. gr. 50 ; Noise insulation - ex‐
ploded view .
– Connect ⇒ Vehicle diagnostic tester.

– Carry out the complete basic settings in the Guided
Functions ⇒ page 11 .

– Place plug on »removed« mechatronic unit if necessary.
This means mechatronic unit can be sent sealed in oil-tight con‐
dition.
11 View on selector forks; mechatronic unit is removed
N - Idling/gearbox neutral po‐

sition »in the middle«
R - Reverse
❑ When reverse gear is
engaged, extended
plunger of mechatronic
unit engages behind
gearbox housing.
– Therefore, move me‐
chatronic unit into re‐
moval position by hand
⇒ page 132 .
1 - gear
2 - gear
3 - gear
4 - gear
5 - gear
6 - gear
7 - gear

12 Renewing bellows with clutch actua‐

tor
♦ Cleaning solution, part number: D 009 401 04 ⇒ Electronic
Parts Catalogue (ETKA)
Caution
The mechatronic unit may be damaged.

♦ For effective and problem-free repairs, it is necessary to
work with great care and cleanliness. Furthermore, the
tools must be in perfect condition.
♦ The clutch actuator piston is magnetic. To ensure a high‐
est possible degree of cleanliness, leave the new clutch
actuator in its packaging until the installation.
♦ After the clutch actuator is removed from its packaging, do
not place it anywhere,
permitted unlessbut install it immediately.
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Prerequisite:
The mechatronic unit was removed and the breather hole is
closed so that oil cannot drain out.
Procedure:
– Removing mechatronic ⇒ page 97 .
– Place the mechatronic unit on an even and clean surface, for
example a workshop bench. The oil filler plug -arrow- must
point upwards.
Note
The area around the clutch actuator must always be clean and
dry. The smallest dirt particles can cause leaks later.
12. Renewing bellows with clutch actuator 143

– Clean the area -1- around the clutch actuator with the cleaning
solution D 009 401 04 or using a spray bottle -2- with a cleaner.
Remove stubborn dirt with a brush. Then clean the area -1-
again thoroughly with a lint-free cloth.
Note
Before turning the mechatronic unit, ensure that the breather hole
-arrow- is closed so that oil does not drain out.
– Turn the mechatronic unit to the side so that the clutch actuator
points upwards.
– Pry out the folded bellows -1- of the mechatronic unit using a
screwdriver -2-.
Note
Clean the guide sleeve thoroughly before any work since even
the smallest direct particles can later cause leaks.
– Set the guide sleeve
respect to the -2- with the
correctness large opening
of information upwards
in this document. onbythe
Copyright SEAT S.A.
mechatronic unit, as illustrated, and hold it firmly with one
hand. Pull out the clutch actuator -1- up to the end with the
other hand.
– Remove the guide sleeve carefully. Ensure that the clutch ac‐
tuator -1- is not pulled out further yet.
Proceed with the other clutch actuator in the same way.
Note
Now a crucial inspection must be carried out for the next steps.

– Check if there is a leak in the area around the clutch actuator

-1-.
If the area -1- around the clutch actuator is dry, continue as fol‐
lows: ⇒ page 145 .
If there is oil in the area, the oil must be drained from the mecha‐
tronic unit before the next step
⇒ “16.2 Draining and filling hydraulic fluid for mechatronic unit”,
page 196 .
Note
Do not fill any hydraulic fluid before the following work is carried
out.
Continuation in any case:
– Place the mechatronic unit in such a way that the oil filler plug
-arrow- points upwards.
– Clean the area around the seal -2- with the cleaning solution
D 009 401 04 or using a spray bottle -1- with a cleaner. Wait
until the cleaner has drained, or dry it using a lint-free cloth.

– Place the mechatronic unit in such a way that the clutch ac‐
tuator points upwards. Ensure that the breather hole -arrow-
is closed so that oil does not drain out.
Note
It is very important to proceed with great care and cleanliness

when carrying out any work. It is therefore absolutely necessary
to ensure that the clutch actuator does not infiltrate any dirt in the
opening when removing it.
– Pull the clutch actuator from the mechatronic unit.

Installation
Caution
The mechatronic unit may be damaged.

♦ For effective and problem-free repairs, it is necessary to
work with great care and cleanliness. Furthermore, the
tools must be in perfect condition.
♦ The clutch actuator piston is magnetic. To ensure a high‐
est possible degree of cleanliness, leave the new clutch
actuator in its packaging until the installation.
♦ After the clutch actuator is removed from its packaging, do
not place it anywhere, but install it immediately.
Note
Clean the guide sleeve thoroughly before any work since even
the smallest direct particles can later cause leaks.
– Grease the sealing lip -arrow- of the seal -2- lightly with oil and
guide the guide sleeve -1- up to the end.
– Lead the clutch actuator -1- carefully in the opening of the me‐
chatronic unit using the guide sleeve -2-. Hold the guide sleeve
firmly with one hand and lead the clutch actuator approx. 30
mm. in the mechatronic unit with the other hand.
– Remove the guide sleeve carefully. The piston must not be
pulled out again when doing so.
– Carefully lead the clutch actuator further into mechatronic unit
until bellows rest against opening.

– Fasten the bellows -1- with the detent -2- in the mechatronic
unit by pressing it down with four fingers.
– Install the other clutch actuator in the same way.
– Remove the old seal of the mechatronic unit and clean the nut
(-shown in green-) before installing a new seal.
Note
The seal can be installed only in one particular position.
– Fit the new seal in the nut in the mechatronic unit. The nose
of the seal lower -arrow- must
Protected align Copying
by copyright. with the recess
for private in the me‐
or commercial purposes, in part or in whole, is not
chatronic unit -upper arrow-.
– If the oil was drained from the mechatronic unit, fill the oil
⇒ page 196 .
– Installing mechatronic ⇒ page 134 .

13 Breather hose of mechatronic unit for

dual clutch gearbox - J743- : remov‐
ing and fitting
⇒ “13.1 Breather hose of mechatronic unit for dual clutch gearbox
J743 : removing and fitting, Ibiza 2008 ►, Ibiza ST 2010 ►”, page
148
⇒ “13.2 Breather hose of mechatronic unit for dual clutch gearbox
J743 : removing and fitting, Leon 2009 ►”, page 149
13.1 Breather hose of mechatronic unit for

dual clutch gearbox - J743- : removing
and fitting, Ibiza 2008 ►, Ibiza ST 2010
►
Removal:
TSI engines with 1.2 l - 77 kW and 1.4 l - 110 kW TSI engines with
the battery in the engine compartment.
– Remove battery ⇒ Electrical system; Rep. gr. 27 .
– Unscrew the nuts-1- and screw -2- and remove the battery
support.


– Remove the breather hose -3- -arrows- and remove from the
bracket -2-.
– Pull the breather hose from its basis -4- upwards in the direc‐
tion of the -arrow-.
– Apply a suitable plug from the sealing plug set - VAS 6122- to
achieve an oil-tight seal of the exposed breather line of the
mechatronics.
Installation
Note
Pull the hose upwards slightly to ensure that the basis of the
breather hose has engaged correctly on the breather line of the
mechatronics.
13.2 Breather hose of mechatronic unit for

dual clutch gearbox - J743- : removing
and fitting, Leon 2009 ►
Removal:
– Remove complete air filter housing ⇒ 4 cylinder Engine with
direct petrol injection 1.8 Turbo 4 V; Rep. gr. 24 ; Fuel prep‐
aration, injection
13. Breather hose of mechatronic unit for dual clutch gearbox J743 : removing and fitting 149
– Remove the breather hose -3- -arrows- and remove from the
bracket -2-.
– Pull the breather hose from its basis -4- upwards in the direc‐
tion of the -arrow-.
– Apply a suitable plug from the sealing plug set - VAS 6122- to
achieve an oil-tight seal of the exposed breather line of the
mechatronics.
Installation
Note
Pull the hose upwards slightly to ensure that the basis of the
breather hose has engaged correctly on the breather line of the
mechatronics.

14 Gearbox : removing and fitting

⇒ “14.1 Gearbox removal, Ibiza 2008 ►, Ibiza ST 2010 ►”,
page 151
⇒ “14.2 Removing gearbox; Ibiza 2008 ► with 1.4 l and 132 kW
petrol engine”, page 156
⇒ “14.3 Gearbox: removing, Altea 2009 ►, Altea XL 2009 ►, Leon
2009 ►”, page 167
⇒ “14.4 Remove gearbox, Toledo 2013 ►”, page 173
⇒ “14.5 Installing gearbox”, page 180
⇒ “14.6 Tightening torques to attach the gearbox to the engine
and information on the gearbox mounting”, page 184
14.1 Gearbox removal, Ibiza 2008 ►, Ibiza ST

2010 ►
Brief description
The gearbox is removed downwards separately, without engine.
»From above«
Remove battery and starter.
»From below«:
Remove noise insulation beneath engine, front left wheel housing
liner and subframe with pendulum support. The drive shafts are
to be secured so that they do not get in the way during removal,
but without removing them from the suspension struts. The gear‐
box is removed downwards separately, without engine.
Subframe must be secured.
14. Gearbox : removing and fitting 151

Special tools and workshop

equipment required
♦ Engine and gearbox jack -
SAT 1040-
♦ Gearbox support -
T20138C -
♦ Base plate - T20145-
♦ Engine support - U30025F-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Adapter for the hydraulic engine and gearbox jack - SAT

1001/1-
Work sequence
Note
♦ Observe rules for cleanliness when working on gearbox
⇒ page 13 .
♦ Refer to general repair instructions ⇒ page 7 .
♦ All cable ties which are released or cut open when removing
the gearbox must be refitted in the same position when instal‐
ling the gearbox.
– Raise the vehicle. In doing so, place the supports of the lifting
platform at the same height.
– With ignition switched off, disconnect battery earth strap.

1.4 l TSI engine 110

– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
and installing air filter .
Engine SRE 1.6 l - 77 kW
– Remove the first intake manifold lower of the intake system.
Caution

Vehicles with battery located in engine compartment

– Remove the battery and bracket ⇒ Electrical system; Rep. gr.
27 .
– Unscrew the nuts-1- and screw -2- and remove the battery
support.
Later, during installation, please check whether both breather

caps are seated on gearbox.

– Unscrew bolt -1- from bracket -2- of the breather hose and
remove.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
and installingpermitted
starter . authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
unless

– Hang-out the selector lever control cable -2- from the lever of
the selection shaft.
– Pull off securing clip -1- for selector lever cable.
Note
♦ A lock washer, which was removed, never insert again. The

clip will have lost its internal tension and so it might fall off.
♦ This is why a new circlip must always be used when assem‐
bling.
– Remove cable with great care from cable support bracket on

gearbox. Do not bend it.
Cable may also be pushed slightly backwards out of cable support
bracket and removed later when gearbox is lowered. But then
observe cable when lowering gearbox.

– Then unscrew all upper securing bolts between engine and
gearbox. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
One screw is located in the opening of the starter. The socket -

T10061- can be used instead of the 18 mm socket.
– remove the central sound proofing ⇒ Exterior body installation
work; Rep. gr. 50
– Remove the left and right wheel box cover ⇒ Exterior body
installation work; Rep. gr. 66

The number of electrical connectors on the bracket described be‐

low may vary depending on the engine model.
– Remove all brackets in front of the plug connection of the
gearbox.
– Remove articulated shaft from the flange shaft of the gearbox
⇒ Running gear, shafts, steering; Rep. gr. 40 .
– Dismount the front subframe⇒ Front wheels suspension; Rep.
gr. 40 ; Subframe .
1.4 l - 110 kW TSI engine
– Remove the front section (catalytic converter) of the exhaust
system ⇒ 4-cylinder injection engine (1.4 l, four direct-injection
valves, turbocharger and rotary piston compressor); Rep. gr.
26 ; Exhaust system
– Remove the front section of the exhaust system ⇒ 4-cylinder
haust system .
– Remove the front section of the exhaust system on the un‐
dercarriage.
– If necessary, the engine cover may have to be removed de‐
pending on the engine version.
– Separate the hoses and cables in the engine compartment
near to the retainers that hang in the engine support -
U30025F- .
– Install the engine support - U30025F- . The adjustable position

of the feet must be inclined to the back -arrow- when doing so.
Note permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Fit the supporting equipment so that it is seated correctly on

the hardest parts of the wing water drains and will not cause
any damage.
♦ Ensure that the pipe connections and the cables in the area
where the engine is suspended do not suffer any damage
while fitting the hooks of the support equipment.
– Slightly tense the engine assembly/gearbox via the spindles.
– Extract the attachment bolts -arrows- for the gearbox support.

Always renew.

– Unscrew screw -1- of the console -A- of the gearbox.

– Lower the engine assembly/gearbox with the spindle until the
gearbox console attachment bolts -2- an be accessed from the
wheel housing.
– Unscrew the securing screw -2- of the gearbox console -A-
and remove the console.
– Attach the support tool - T20138C- on the base - T20145- ,

and move these onto the engine and gearbox jack - SAT 1040-
using the adapter for the hydraulic engine and gearbox jack -
SAT 1001/1- .
– Unscrew the remaining lower securing bolts between engine
and gearbox.
– Release the gear box from the centring cases and turn toward
subframes, move the spindles of the gear box carrier -
T20138C-
There are brackets on the front side of the gearbox with certain
versions.
Note
Lower the gearbox very carefully.
– Remove retainers if installing a new gearbox, because there

are no retainers on a new gearbox.
14.2 Removing gearbox; Ibiza 2008 ► with 1.4 l and 132 kW petrol engine


equipment required
♦ Support bracket - 10 - 222
A-
♦ Template - 3282/59-
♦ Socket and key - T10035-
♦ Gearbox support assembly
- 3282-
♦ Insert tool, 18 mm -
T10179-

♦ Socket and key - T10107 A-

♦ Shackle - 10 - 222 A /12-
♦ 2 Tensioning straps -
T10038-
V.A.G 1383 A-

Removal:
– Apply the brakes and loosen the nuts on the drive shafts
-Arrow- on both sides.
Note
After loosening centre nut, do not lower vehicle to ground again.

height.
Caution

age to electronic components: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Observe the measures to be adopted whento disconnecting
respect the correctness of information in this document. Copyright by SEAT S.A.
– Disconnecting battery ⇒ Rep. gr. 27 ; Connecting and dis‐

connecting battery in the luggage compartment, disconnecting
and reconnecting battery .
– Lift up the engine cover at points -1- and slide this forward in
the direction of the -arrows-.
– Take off the hose -1- on the suction hose.

– Open the elastic spring band clamp -2- and take off the suction
hose.
– Take off the hose -3- on the suction inlet.
– Screw out the fastening bolt and pull on the air filter housing
-4-, in order to move it upwards.

– Unscrew main fuse box. First unscrew bolts -1-, then lift up
printed circuit board and unscrew bolt -2-.
– Box can then be placed to side in order to gain access to bolts
-3-.

and installing starter .
Note

bling.
Remove cable with great care from cable support bracket on

gearbox. Do not bend cable.

– Release mechatronic unit connector by pulling and pull off
connector.

– Screw out the bolts -Arrows- of the heatshield -1- on the tur‐
bocharger.
– Screw the flange on the inlet manifold -1- out.
Note
Leave out further positions.
– Screw the top fastening nuts of the turbocharger -Arrows- out.
– If fitted: remove filler pieces from upper edges of both wings.

– Support engine and gearbox, but do not raise.
– Remove noise insulation ⇒ Rep. gr. 50 ; Underseal .

– Separate both plug-in connectors -Arrows- of the lambda

probe behind the catalyser - G130- and the lambda probe itself
- G39- .
– Loosen the cable bunch of the alternator, the lambda probe

behind the catalytic converter - G130- and the lambda probe
- G39- from the fasteners -arrows-.
– Screw out lambda probe behind the catalyser - G130- with the
wrench set - 3337- and take it off.
– Screw out the bottom fastening nuts of the
respect to theturbocharger
correctness of information in this document. Copyright by SEAT S.A.
-Arrows-.
– Remove the left-hand charge air hose; loosen the hose clamps
to do this -Arrows-.

– Screw out the fastening bolt -1- of the charge air hose.
– Unscrew the fastening bolts -4- and remove the bracket -5-.
– Take the charge air hose off downwards.
Note
Disregard items -2- and -3-.
– Loosen the fastening nuts of the intake manifold -Arrows- and

push it towards the back.
– Remove the mountings -Arrows- of the exhaust pipe attach‐

ment from their brackets.
– Remove the catalyser and pre-silencer in downward direction.
– Remove front left-hand wheel housing ⇒ Rep. gr. 66 ; Wheel
housing liner .
– Detach hexagon nuts -1- of the coupling rod left and right-hand
sides.
– Remove the tie rod -3- from the stabilizer on the left and right-
hand sides -2-.

– Unscrew the bolts on both sides of the drive shaft from the stub
shaft / gearbox -Arrows-.
– Detach the outer joint on the wheel hub on both sides by hand.
– Unscrew the nuts-Arrows- on both sides.

– Separate the wheel bearing housing from the swivel joint of
the transverse rocker arm
– Remove the drive shafts
– Remove right flange shaft of gearbox using socket - T10107

A- .
Bolt has a 6 mm hexagon socket. Bolt can also be removed and
installed with socket - V.A.G 1669- .
– Screw 2 bolts into flange and counterhold flange shaft with a

lever in order to remove and install flange shaft.
– Remove flange shaft with compression spring.
– Close opening in drive shaft using a suitable plug.
– To install flange shaft, if necessary press against gearbox with
a lever and screw in bolt.
Tightening torque: 30 Nm.

– Unbolt the steering gear from the power train carrier

-Arrows- and attach it e.g. using wire.
– Fix position of subframe ⇒ Rep. gr. 40 .
– Lower the power train carrier with the engine and gearbox jack
- V.A.G 1383 A- .
During removal, it is recommended to remove the lower bolt first.
These tools are appropriate for this.
– Remove all upper connecting bolts between engine and gear‐

box.


Remove 3 bolts from bracket.

2 bolts vertical, 1 bolt horizontal on top of gearbox.
– Then lower engine and gearbox slightly using spindle of sup‐

port bracket - 10 - 222 A- until lower bolts of bracket can be
removed.
In many cases, the spindle does not need to be lowered further
for the later removal of the gearbox.
– Set up gearbox support - 3282- with adjustment plate -
3282/59- .
– Move engine and gearbox jack - V.A.G 1383 A- under gearbox

and support gearbox. Do not raise.

– Position plate of pin under gearbox housing, not under me‐
chatronic unit.
– A pin is screwed into the rear hole for the pendulum support.
The gearbox is separated from the engine in this position.
– Remove remaining engine/gearbox connecting bolts.
– Press gearbox off engine, »observing selector lever cable«
and lower gearbox.

versions.
– Remove retainers.
When a new gearbox is fitted these mounts are not on the new
gearbox.
– Install right flange shaft again.
– For subsequent installation, check whether both breather caps

are seated on gearbox.
14.3 Gearbox: removing, Altea 2009 ►, Altea

XL 2009 ►, Leon 2009 ►
Transporting gearbox and securing to assembly stand
⇒ page 191 .
Tightening torques to attach the gearbox to the engine and infor‐
mation on the gearbox mounting ⇒ page 184


equipment required
SAT 1040-
♦ Gearbox support -
T20138C -
♦ Base plate - T20145-
♦ Engine support - U30025F-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Adapter for the hydraulic engine and gearbox jack - SAT

1001/1-
Work sequence
Note
♦ Observe rules for cleanliness when working on gearbox

⇒ page 13 .
♦ Refer to general repair instructions ⇒ page 7 .
♦ All cable ties which are released or cut open when removing
the gearbox must be refitted in the same position when instal‐
ling the gearbox.
– Raise the vehicle. In doing so, place the supports of the lifting
platform at the same height.
– With ignition switched off, disconnect battery earth strap.
– Remove complete air filter housing ⇒ 4 cylinder Engine with
direct petrol injection 1.8 Turbo 4 V; Rep. gr. 24 ; Fuel prep‐
aration, injection

– Remove battery ⇒ Electrical system; Rep. gr. 27 .

– Remove battery tray -arrows-.

– Unscrew bolt -1- from bracket -2- of the breather hose and
remove.

Note

bling.
– Remove cable with great care from cable support bracket on


gearbox.

T10061 - can be used instead of the 18 mm socket.
– remove the central sound proofing ⇒ Exterior body installation
work; Rep. gr. 50
The number of electrical connectors on the bracket described be‐

low may vary depending on the engine model.
– Remove all brackets in front of the plug connection of the
gearbox.

– Remove pendulum support.
– Press »engine and gearbox« forwards and secure in position

with an appropriate piece of wood -A-.
– Pay special attention to the following points:
• The alternator should not rub more than lightly on the refrig‐
erant tubes.
• The air conditioning compressor should not rub more than
lightly on the refrigerant tube connections.
– Remove the heat shield (when fitted) of the right hand side
wheel drive shaft -arrows-.
– Remove articulated shaft from the flange shaft of the gearbox
⇒ Running gear, shafts, steering; Rep. gr. 40 .
– Unbolt exhaust system retainer.

– If necessary, the engine cover may have to be removed de‐
pending on the engine version.
– Separate the hoses and cables in the engine compartment
near to the retainers that hang in the engine support -
U30025F- .

– Fit the engine support - U30025F- on wing panel flanges.

– Place eyes onto spindle hooks.
Note
♦ Fit the supporting equipment so that it is seated correctly on

the hardest parts of the wing water drains and will not cause
any damage.
♦ Ensure that the pipe connections and the cables in the area
where the engine is suspended do not suffer any damage
while fitting the hooks of the support equipment.
– Slightly tense the engine assembly/gearbox via the spindles.
Remove all bolts -1- and -2- for bracket.

– Then lower the engine / gearbox unit a little using the spindle
of the engine mount - U30025F- in order to remove the con‐
sole.
– Attach the support tool - T20138C- on the base - T20145- ,

and move these onto the engine and gearbox jack - SAT 1040-
using the adapter for the hydraulic engine and gearbox jack -
SAT 1001/1- .
– Unscrew the remaining lower securing bolts between engine
and gearbox.
– Release the gear box from the centring cases and turn toward
subframes, move the spindles of the gear box carrier -
T20138C -
versions.
Note
Lower the gearbox very carefully.


14.4 Remove gearbox, Toledo 2013 ►

Transporting gearbox and securing to assembly stand
⇒ page 191 .
Tightening torques to attach the gearbox to the engine and infor‐
mation on the gearbox mounting ⇒ page 184

equipment required
♦ Support bracket - 10 - 222
A-
♦ Template - 3282/59-
♦permitted
Socket and key - T10035-

- 3282-
♦ Insert tool, 18 mm -
T10179-


♦ Shackle - 10 - 222 A /12-
♦ 3 Tensioning straps -
T10038-
V.A.G 1383 A-
Brief description
The gearbox is removed downwards separately, without engine.
»From above«
Remove battery, air filter and starter.
»From below«:
Remove noise insulation beneath engine, lower cover in front left
wheel housing and pendulum support.
Removing:
height.

– Remove battery and -battery tray- ⇒ Rep. gr. 27 ; Battery;

Removing and installing battery .
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Removing
and installing air filter .
– Remove battery tray -arrows-.

– Remove selector lever cable from ball head, remove securing

clip.
A securing clip which has been removed is not allowed to be in‐
stalled again. The clip will have lost its internal tension and so it
might fall off.
– Therefore, when installing, always use a »new« securing clip.
Remove cable with great care from cable support bracket on
Cable may alsoProtected
be pushed slightly
by copyright. backwards
Copying out of cable
for private or commercial support
purposes, in part or in whole, is not
bracket and removed later
permitted unless whenbygearbox
authorised SEAT S.A. SEATis lowered.
S.A does not But then

– Release mechatronic unit connector by pulling and pull off

connector.
gearbox.

These tools are appropriate for this.

exploded view .
– If fitted, remove the heat shield over the right-hand drive shaft.
Tightening torque ⇒ Rep. gr. 40 ; Repairing drive shafts

– Unbolt left suspension link from suspension strut.

– Swing left drive shaft into wheel housing onto longitudinal
member. This will keep the shaft out of the way during further
work.
The surface protection of the shafts must not be damaged. Plastic
cable ties or a pair of tensioning straps - T10038- are therefore
very good for this.
Secure both drive shafts to suspension struts using tensioning

straps - T10038- .
– Remove right flange shaft of gearbox using socket - T10107

A- .
– Screw 2 bolts into flange and counterhold flange shaft with a

lever in order to remove and install flange shaft.
– Remove flange shaft with compression spring.
– Close opening in drive shaft using a suitable plug.
– To install flange shaft, if necessary press against gearbox with
a lever and screw in bolt.

– Remove pendulum support.
– Unbolt exhaust system bracket from subframe ⇒ Rep. gr. 26 ;

Removing and installing parts of exhaust system .
– Disconnect front exhaust pipe from catalytic converter so that

lower engine/gearbox connecting bolts -arrows- can be re‐
moved ⇒ Rep. gr. 26 ; Removing and installing parts of
exhaust system .
– Remove engine cover from cylinder head.
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10-222A- , remove these now.
– If fitted: remove filler pieces from upper edges of both wings.

– Support engine and gearbox, but do not raise.
Remove 3 bolts from bracket.

2 bolts vertical, 1 bolt horizontal on top of gearbox.
– Then lower engine and gearbox slightly using spindle of sup‐

port bracket - 10 - 222 A- until lower bolts of bracket can be
removed.
In many cases, the spindle does not need to be lowered further
for the later removal of the gearbox.
– Set up gearbox support - 3282- with adjustment plate -
3282/59- .
– Move engine and gearbox jack - V.A.G 1383 A- under gearbox

and support gearbox. Do not raise.
– Position plate of pin under gearbox housing, not under me‐
chatronic unit.by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
– Screw a pin into »rear« hole for pendulum support.
The gearbox is separated from the engine in this position.

– Remove remaining engine/gearbox connecting bolts.
– Press gearbox off engine, »observing selector lever cable«
and lower gearbox.

versions.
Gearbox with flange shafts, torque setting ⇒ page 294
14.5 Installing gearbox

Installation is carried out in the reverse order. However, the fol‐
lowing important steps must be observed:
Note
♦ Renew self-locking nuts and bolts.

♦ Renew O-rings, seals, gaskets
permitted unless and bolts
authorised which
by SEAT S.A. are
SEATtightened
S.A does not guarantee or accept any liability with
by turning through a specified
respect angle.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic Parts Catalog “ET‐
KA” .
♦ All cable ties which were opened or cut during removal must
be renewed at the same points.
♦ Clean the cogs of the drive shaft and the teeth of the speed
damper, eliminate corrosion and apply a very fine layer of lu‐
bricating grease to the cogs (allocation ⇒ Electronic Parts
Catalog “ETKA” ). It is essential to remove excess grease.
– If no dowel sleeves for centralising engine/gearbox are in the

cylinder block, install dowel sleeves.
– There are brackets on the front side of the gearbox that have
been removed with certain versions. These brackets must be
mounted on the new gearbox.


– Remove right-hand flange shaft of gearbox in order to install
gearbox.
Gearbox with flange shafts, torque setting ⇒ page 294
– Renew needle bearing -arrow- in crankshaft⇒ Rep. gr. 13 ;

Crankshaft; Renewing needle bearing in crankshaft
Note
If the needle bearing in the crankshaft is damaged, the gears

cannot be selected properly anymore because the clutch is sup‐
ported on this bearing.
– Clean input shaft splines and splines of torsional damper, re‐

move corrosion and lubricate splines with only a very thin
coating of grease ⇒ Electronic Parts Catalog (ETKA) . Elimi‐
nate excess grease.
– Check for proper seating of both dowel sleeves between en‐
gine and gearbox.
– Check for proper seating of intermediate plate.
Pay attention to selector lever cable when raising gearbox. Insert
the cable into the support bracket as soon as possible.
Do not lubricate the cable!
It must be possible to guide the engine and gearbox together by
hand until the engine flange and gearbox flange make contact all
around.
If not, »something has gone wrong«!
– Re-adjust gearbox support until engine and gearbox »are
aligned with each other«.
– When necessary, turn the crankshaft a little.

– Take great care with both breathing flaps, especially after fit‐
ting the starter.

– Install the bracket -2- of the breather hose and tighten screw
-1- to a tightening torque of 30 Nm.
– Installing the breather hose:
♦ Leon 2009 ► ⇒ page 149
– The locking ring of the selector lever cable must be replaced.

A securing clip which has been removed is not allowed to be in‐
stalled again. The clip will have lost its internal tension and so it
might fall off.
– Therefore, when installing, always use a »new« securing clip.
– If cable support bracket -1- has been removed, bolt it to gear‐

box -arrows-.

– Ensure that selector lever cable is properly routed during in‐

stallation.
If the sheet metal has been bent downwards when the gearbox
was removed, it may cause noises. The cable »will vibrate«
against the sheet metal.
– Take care of the plate. Press it back up in the tunnel during
installation.
– Always adjust the selector lever cable ⇒ page 90 .
– Fit the articulated shaft to the flange shaft of the gearbox ⇒
Running gear, shafts, steering; Rep. gr. 40 .
Gearbox assembly mounting tightening torques ⇒ page 184
– Install the front section (catalyser) of the exhaust system ⇒ 4
cylinder injection engine (1.4 l, four direct injection valves, tur‐
bocharger and rotary piston compressor); Rep. gr. 26 ; Ex‐
haust system
– Install the front section of the exhaust system ⇒ 4-cylinder
haust system .
Continuation for all vehicles:
– Fit the front subframe⇒ Front wheels suspension; Rep. gr.
40 ; Subframe .
– Fit the articulated shaft to the flange shaft of the gearbox ⇒
Running gear, shafts, steering; Rep. gr. 40 .
Vehicles with battery located in engine compartment
– Install battery ⇒ Electrical system; Rep. gr. 27 .
– Then install complete air filter housing:
• 1.4 l - 110 and 132 kW, 1.6 l - 75 kW, 1.8 l - 118 kW engines
⇒ Rep. gr. 24 ; air filter: removing and installing
• 1.6 l - 77 kW CR TDI engine ⇒ Rep. gr. 23 ; air filter: removing
and installing
Engine SRE 1.6 l - 77 kW
– Fit the first intake manifold of the intake system.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and connecting battery .
– Connecting
Protected theforVehicle
by copyright. Copying diagnostic,
private or commercial testing
purposes, in partand information
or in whole, is not
system
– Carry out the complete basic settings in the Guided
Functions ⇒ page 11 .
Gearbox assembly mounting tightening torques ⇒ page 184

14.6 Tightening torques to attach the gear‐

box to the engine and information on the
gearbox mounting
The next chapters list the torque settings for gearbox installation.
There is also information about the »left« assembly mounting.
The screw connections that have not been directly assigned to
the gearbox can be obtained in the respective assembly groups.
Example: Subframe and hinged support:
The pendulum support of the subframe are a part of the running
gear.
Consequently, further descriptions can also be found in ⇒ Run‐
ning gear; Rep. gr. 40 .
– Route the selector lever control cable correctly during the as‐
sembly.
If the plate is bent downwards, this may cause noises. The cable
then »rattles« against the plate.
– Take care of the plate. During the assembly, this must be
pushed upwards against the tunnel.
– Replace all the bolts on the left fastening of the engine as‐
sembly.
– First screw in all bolts by hand.
Ibiza 2008 ►, Ibiza ST 2010 ►, Toledo 2013

– Fit the gearbox console -A- and tighten the securing bolts
-1 and 2- to a torque of 40 Nm + 90°.
– Mount the gearbox bearings and tighten the screws -arrows-

to 40 Nm + 90°.

Altea 2009 ►, Altea XL 2009 ►, Leon 2009 ►

– The bracket can be moved within its seat with a screwdriver
when bolts -2- are tightened. Tightening torque for -bolts 2:-
60 Nm + 90°.
– First bolt bracket to gearbox -1- with 40 Nm +90° further turn.

Continuation for all vehicles:
Starter to gearbox ⇒ Rep. gr. 27 ; Removing and installing start‐
er .
Front section of the exhaust system ⇒ Rep. gr. 26 ; Exhaust
system
Front subframe⇒ Front wheels suspension; Rep. gr. 40 ; Sub‐
frame .
Ibiza 2008 ►, Ibiza ST 2010 ►:
♦ Engine 1.2 l - 77 kW TSI ⇒ page 185 .
♦ Engines 1.4 l - 110 kW TSI and 1.4 l - 132 kW TSI
⇒ page 187 .
♦ Engine SREunless
permitted 1.6 authorised
l - 77 kW ⇒ page
by SEAT 188S.A. does not guarantee or accept any liability with
S.A. SEAT
Leon 2009 ►:
♦ Engine SRE 1.6 l - 75 kW ⇒ page 189 .
♦ 1.6 l - 77 kW CR TDI and 1.8 l - 118 kW TFSI engines
⇒ page 190 .
Toledo 2013 ►:
♦ Engine 1.4 l - 90 kW TSI ⇒ page 187 .
14.6.1 1.2 l - 77 kW TSI engine

M12 - 80 Nm.
M10 - 40 Nm.
- The arrows show the dowel
sleeves.

14.6.2 1.4 l - 110 kW TSI engine / 1.4 l - 132 kW TSI engine / 1.4 l - 90 kW TSI
engine
M12 - 80 Nm.
M10 - 40 Nm.
sleeves.

14.6.3 1.6 l - 77 kW SRE engine
M12 - 80 Nm.
M10 - 40 Nm.
sleeves.

14.6.4 Engine 1.6 l - 75 kW SRE
M12 - 80 Nm.
M10 - 40 Nm.
sleeves.

14.6.5 1.6 l - 77 kW CR TDI and 1.8 l - 118 kW TFSI engines
M12 - 80 Nm.
M10 - 40 Nm.
sleeves.

15 Transporting gearbox and securing to assembly stand

equipment required
♦ Lifting eyes - 10 222A/12-
♦ Support equipment -
2024A-
♦ Hooks - 3368-
♦ Support - VW 309-
- VW 353-
Transporting the gearbox.
15. Transporting gearbox and securing to assembly stand 191

– Pull off both breather caps -arrows- and close using suitable
plugs to achieve an oil-tight seal.
Caution
Risk of damage to the gearbox.

♦ It is not possible to check the fill level of the hydraulic fluid
part of the mechatronic unit for dual clutch gearbox -
J743- . Before repairs, the breather of the mechatronic unit
for dual clutch gearbox - J743- must be sealed so that no
oil can escape.
♦ Several vehicles have a breather hose mounted on the
mechatronic unit breather. Before assembly work, the
hose must be removed and the breather of the mecha‐
tronic unit for dual clutch gearbox - J743- must be sealed
so that no oil can escape.
♦ If any oil escapes from the hydraulic fluid part of the me‐
chatronic unit for dual clutch gearbox - J743- , it is not
possible to replenish it or check the level!
♦ If oil escapes from the gear oil part, it can only be rectified
by changing the gear oil. It is not possible to check the fill
level.
♦ If the level of oil/fluid is too high or too low in either of the
parts, the function of the gearbox will be impaired.
– Remove both sealing caps -arrow- and seal the opening so

that oil cannot escape using a clean plug fromunless
permitted the authorised
sealingbyplug
SEAT S.A. SEAT S.A does not guarantee or accept any liability with
set - VAS 6122- . respect to the correctness of information in this document. Copyright by SEAT S.A.
• After fitting the gearbox in the vehicle, the plugs must be re‐
moved and the breather caps must be refitted.

– Removing and installing the breather hose:
♦ Leon 2009 ► ⇒ page 149
Secure gearbox on gearbox support - VW 353- .

Lift the gearbox onto the assembly stand.

The gearbox is fixed to the holder - VW 353- and lifted onto the
»assembly stand«. For this purpose use the tension belt -
2024A- .
15. Transporting gearbox and securing to assembly stand 193

16 Gearbox oil
16.1 Renewing gear oil

♦ Used oil collection and extraction unit - V.A.G 1782-
♦ Adapter for oil filling - VAS 6262 A-
♦ Extension - VAS 6262/7- permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
The gearbox is filled for life. Therefore, there is no need to check

the oil level of this gearbox.
This explains why there is no oil level check.
If the gearbox has started leaking, check where the oil is coming
from.
– Position used oil collection and extraction unit - V.A.G 1782-
under gearbox.

– Then drain remaining oil.

– Repair leak.
– Then install the drain plug again.
The new oil is poured in through the breather hole.

If the gearbox has been installed, the air filter and/or battery must
be removed in order to fill it with oil, depending on the model and
engine size.
Removing and installing air filter housing ⇒ Rep. gr. 24 .
– Remove battery and -battery tray- ⇒ Rep. gr. 27 ; Battery;
Removing and installing battery .
– Pull cap off breather hole.
– Fit oil filling adapter - VAS 6262 A- with adapter - VAS 6262/4-
on breather hole.
Note
♦ Only the gear oil for the 7-speed dual clutch gearbox 0AM,
which is available through the replacement parts system, may
be used ⇒ Electronic Parts Catalog (ETKA) .
♦ Shake oil bottles before filling.
♦ Breather pipe of adapter for oil filling - VAS 6262 A- may need
to be shortened.
16. Gearbox oil 195

– In order to ensure that the breather pipe of the adapter for oil
filling - VAS 6262 A- does not contact the bottom of some oil
bottles, the pipe must be shortened to the length -a-.
Dimension -a- = 182 mm
Note
The dimension -a- is measured from the shaft (green area in the
counting glass) of the adapter for oil filling - VAS 6262 A- .
– Mark dimension -a- on the breather pipe and shorten pipe with
pipe cutter - VAS 6056/2- .
– Bolt extension - VAS 6262/7- onto bottle. Then screw on,

adapter for oil filling - VAS 6262 A- .
– Filling up with oil.
Filling quantity
Capacities after draining oil for general repair work 1.7 l
Capacity after draining and extracting oil for removal 1.9 l
and installation of the mechatronic unit
The oil is available as a replacement part; Part no. ⇒ Electronic
parts catalogue (ETKA) .
After filling, remove oil filling adapter - VAS 6262 A- . Clean area
around breather hole with a cloth and fit the breather cap.
16.2 permittedrespect
Draining
unless and
authorised by filling
SEAT S.A. hydraulic
SEAT S.A fluid
does not guarantee forany liability with
or accept
mechatronic unit

♦ Used oil collection and extraction unit - V.A.G 1782-
♦ Standard seat belt latch opening

The hydraulic fluid of the mechatronic unit lasts for life. The oil
level cannot be checked.
Caution
Risk of damaging mechatronic unit.

♦ Only the specific hydraulic fluid for the mechatronic unit,
available as an accessory, must be used ⇒ Electronic
parts catalogue (ETKA) .
♦ Using other oils could cause malfunctions or damage the
mechatronic unit.
♦ It is not possible to check the oil level in the hydraulic oil
circuit of the mechatronic unit - J743- . To carry out the
assembly work, the breather hole of the mechatronic unit
- J743- must be closed so that oil cannot drain out. If oil
drains out from the hydraulic fluid circuit of the mecha‐
tronic unit - J743- , the oil level cannot be checked!
♦ If the hydraulic fluid should drain out, the oil level can be
adjusted properly only through an oil change. It is not pos‐
sible to carry out a filling level check.
♦ A very high or a very low oil level has an adverse effect on
the functioning of the mechatronic unit.
Prerequisite:
♦ The mechatronic unit was removed ⇒ page 97 .
16. Gearbox oil 197

Draining hydraulic fluid

– Remove oil filler plug -arrow-.
Renew oil filler plug after each removal.
– If not already done, remove the cap of the breather hole

-arrow-.
WARNING

Note
When turning the mechatronic unit, oil drains out from the oil filler
hole as well as the breather hole. Ensure that both holes remain
in the drip tray of the drip and extraction unit for old oil - V.A.G
1782- .
– Turn the mechatronic unit and drain all the oil.

Filling with hydraulic fluid:
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Do not fill any new oil until all the repair work on the mechatronic
unit has been completed.
– After all the oil has drained out, turn the mechatronic unit
again. The oil filler hole must point upwards.

– Fit a standard, clean seat belt latch opening in the oil filler hole.
Shake the oil bottle before opening it.
– Fill 1 l of hydraulic fluid.
– Install a new oil filler plug.
Tightening torque: 5 Nm + 90°
Caution
Risk of damaging mechatronic unit.

♦ If the hydraulic fluid should drain out, the oil level can be
adjusted properly only through an oil change. It is not pos‐
sible to carry out a filling level check.
♦ A very high or a very low oil level has an adverse effect on
the functioning of the mechatronic unit.
– Close the mechatronic unit with a clean sealing plug from the
engine bung set - VAS 6122- so that oil cannot be drained.
This prevents the oil from draining out during the assembly
work.
– Installing mechatronic ⇒ page 134 .
16. Gearbox oil 199

35 – Gears, shafts
1 Notes on gearbox disassembly
Gearbox spare parts are allocated to gearbox code.
For every installation on shafts, always check »lower« bearing. It
is easy for bearing cages to become bent and damaged by
»bumping«.
Bearing races are not allowed to be swapped over. They are
paired with the bearing.
Always renew the bearings on a shaft together.
– Install with care, without using force.
Example:
Always use guide pins - 3411- to install differential. Take care not
to bump lower bearing.
1.1 Overview: gearbox disassembly
200 Rep. gr.35 - Gears, shafts

A - Outer input shaft

I - Input shaft on the inside
1 - Output shaft 1
2 - Output shaft 2
3 - Output shaft 3
1. Notes on gearbox disassembly 201

2 Dismantling gearbox
– Secure gearbox to stand ⇒ page 191 .
Conditions
• Clutch is removed
• Mechatronic unit is removed
• Gear oil is drained
– Engage parking lock.
– Remove cable support bracket.
– Remove parking lock ⇒ page 291 .

– Remove dual clutch ⇒ page 17 .by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected

– If that has not already been completed, remove both engaging

levers.
– Remove mechatronic unit ⇒ page 97 .
– Remove flange shafts or stub shafts ⇒ page 294 .
– Remove connecting bolts of housing halves at clutch end.
– Fit support bridge - T10323- and rotate spindle against inner

input shaft until finger tight.
This supports shaft. Gearbox housing is pulled off later. In this
way, the force required is not applied to the gearbox in an uncon‐
trolled manner.
– Turn gearbox, remove remaining connecting bolts of housing

halves.
2. Dismantling gearbox 203

– Penetrate cover of “inner input shaft” and lever out.

Drive screwdriver »centrally« and at a very »acute« angle into
cover. Only far enough so you can lever out cover.
– Remove the securing ring.

– Remove dowel sleeves of mechatronic unit.
– From above, mount another puller.

Hand tighten square headed bolts - T10427/1- -A- and bracket -
T10427- -B-.
Spindle should press against input shaft.
– Whilst pulling off, you can apply »targeted« hammer blows to
reinforce pulling force.
– Use a hardwood block as protection.
This will make it easier to release glue between both housing
halves.
– Pull off gearbox housing and place it to one side.
Gearbox housing can be clamped in 1 vice for further assembly

with puller.

– Remove magnet and clean it.
– Move selector fork for 1st and 3rd gear upwards into 1st gear.
– Slightly raise output shaft 1, tip it is a little -arrow- and remove
selector fork.
– Move selector fork for 2nd and 4th gear upwards into 4th gear.
– In this case too, raise output shaft 1 slightly, tilt it and remove
selector fork.
– Remove output shaft 1.

– Shift down both remaining selector forks.
– Raise output shafts 2 and 3 out of the lower bearings.
– Place both shafts »in direction of«byselector

Protected forks for
copyright. Copying onto clutch
private or commercial purposes, in part or in whole, is not
housing. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Screw one guide pin - 3411- into differential.

– Remove differential. Output shaft 2 can be raised slightly for
this purpose.

– Remove output shafts 2 and 3.
– Selector forks rotate »inwards«.

– Remove selector forks.
– Remove inner input shaft.

– There is a roller bearing between inner and outer input shaft.
Please also remove this.
• This bearing is not allowed to be broken.
– Unscrew 3 bolts.
– Turn over clutch housing together with »last«, outer input
shaft.

– Lever out outer oil seal.
– Outer input shaft can be pressed out now.

– Hold shaft firmly with one hand. This prevents it from falling
down.
Note
»Pressed out« shaft will fall down.
– Bearing of outer input shaft must always be renewed

⇒ page 228 . New retaining ring -arrow- must also be pressed
in.
Pressing out shaft caused force to be applied through balls of
bearing.
– Clean surfaces of both housings with silicone remover -
LSE020100A3- .
Disassembly of gearbox is completed.
Further »links«:
Assembling gearbox ⇒ page 209 .
Dismantling and assembling gearbox housing ⇒ page 220
Dismantling and assembling clutch housing ⇒ page 224
Dismantling and assembling outer input shaft ⇒ page 228
Dismantling and assembling inner input shaft ⇒ page 230 .
Dismantling and assembling output shaft 1 ⇒ page 233 .
Dismantling and assembling
Protected output
by copyright. Copyingshaft 2 or
for private ⇒commercial
page 244 .
purposes, in part or in whole, is not
Dismantling and assembling output ofshaft
respect to the correctness 3 ⇒ inpage
information 252 . Copyright by SEAT S.A.
this document.

3 Assembling gearbox
Clean sealing surfaces on both gearbox halves.
– First install outer input shaft.
• External input shaft must be prepared for this in advance. 1
new bearing with correct retaining ring must already be at‐
tached ⇒ page 228 .
– Heat clutch housing in area of outer input shaft to approx. 100 °
C using a hot air blower.
• If housing has been heated correctly then outer input shaft can
be inserted by hand up to stop. This is done without force.
If bearing jams then clutch housing is »still too cold«.
Do not continue pressing!
– Remove shaft again, heat clutch housing correctly.
– After cooling down, tighten the 3 screws.

Torque setting 8 Nm + 90°
– Turn
Protected clutch
by copyright. housing
Copying around.
– Drive in outer, »new« oil seal with a plastic mallet until flush
with clutch housing.
WARNING
Only drive in oil seal until flush, in order to avoid closing off oil
drilling located behind it. Otherwise, bearing can no longer be
supplied with enough oil.
– Turn clutch housing back around.
3. Assembling gearbox 209

– Insert inner input shaft with roller bearing.

Bearing is not allowed to be broken. Oil bearing.
– Shift all locking collars of output shafts 2 and 3 »downwards«.
– Insert selector fork for 6th gear and reverse gear.

– Fork cannot be turned in its position unless it is »all the way
down«.
– Insert selector fork for 5th and 7th gears.

This selector fork can be inserted very easily if you raise the other
selector fork a little.

For the following steps:

Tapered roller bearings are destroyed very quickly if the cage is
bent due to being inserted forcefully or knocked.
– Insert output shaft 2.

– Watch out for both locking collars. Mouth »top« and mouth
»bottom« -arrow- must be inserted correctly.
– Output shaft 2 is placed on clutch housing, not in bearing race.
– Insert output shaft 3. by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted unless authorised
– Watch out for mouth of selector fork and locking collar.
This shaft is also »placed« on clutch housing.
– Install differential.
– Make sure that you do not strike bearing against clutch hous‐
ing.
– Carefully insert output shafts into bearings.
– Raise inner input shaft slightly. This allows output shaft 2 to
find its installation position.
– Take out guide pin - 3411- .

– On output shaft 1, shift »upper« locking collar upwards.
– Insert output shaft 1 »at an angle from above«.

Shaft should remain at an angle.
This is because selector forks must still be installed before shaft
is set in installation position.
– First insert selector fork for Protected

2nd and 4th gears into collar then
swivel it to its guide.
– Insert selector fork for 1st - 3rd gears onto collar then swivel it
to its guide.

– Raise inner input shaft slightly. In this way, you can move out‐
put shaft 1 into its installation position.
– After insertion, position all selector forks in neutral.
– Make sure all selector forks and pinion shafts are correctly
seated.
1- Turn shafts.
2- Look at selector forks.
3- Turn gears on shafts a little back and forth. Also on differ‐
ential.
4- Grip inner and outer input shaft from below. Turn shafts
once.
• It must be possible to turn all parts back and forth without
catching.
– Insert magnet.
– Insert dowel sleeves.

It is essential to leave gearbox in this position.
– Mount support bridge - T10323- from below.

– Turn spindle against inner input shaft until finger-tight.

Shaft should only be supported. It is only allowed to be pushed

up until gear for 7th gear on inner input shaft -A- touches syn‐
chromeshed gear for 3rd gear on output shaft 1 -B-.
It is adequate for spindle to touch shaft.
This prevents inadmissible force being applied to gearbox later
on when gearbox housing is put on. Force should be absorbed
by support bridge - T10323- .
– Drip oil onto all exposed tapered roller bearings.
– Prepare gearbox housing to be put on.
• Make sure that gearbox housing is completely assembled.
• Flange surface is cleaned.
• Oil guide is installed.
– Apply a bead of assembly adhesive - AMV 174 003 02- onto

flange of clutch housing.
• »Thickness of adhesive bead«: maximum 1 millimetre.
Adhesive is applied with hand-cartridge gun - V.A.G 1628- .
– Adhesive bead should seal oil space. Therefore, do not spray
around holes.
– Put on gearbox housing.
Note
Do not grip cleaned flange surfaces when putting on gearbox

housing.
– Make sure that selector forks locate in their sockets.
– Place large inner diameter of tube - VW 416 B- onto inner ring.

– When »pressing on« the gearbox housing, a second mechanic
must hold it in position as early as possible.
– Apply targeted blows with a plastic hammer to drive inner input
shaft into its bearing.
– Make sure seating on guide bushes is correct.

– Observe the section of the circlip.

The ring is »smaller at the top«. This corresponds with its fitting
position.
The retaining ring pliers also engage better like this.
– Install new retaining ring.
– Remove support bridge - T10323- from below.
– Screw new connecting bolts against gearbox housing. Do not

tighten them yet.
– In the process of the two halves of the gearbox being tight‐
ened, a second mechanic rotates the gearbox.


– Engage 1st gear for this purpose.
– Use hub of clutch for turning.

This prevents tapered roller bearings from being damaged whilst
being »seated in bearing seat«.
– Tighten new connecting bolts.
Tightening torque
Steel bolts: 20 Nm + 45°
Aluminium screws: 10 Nm + 90°
– Set gearbox to neutral.
– Knock cover of “inner input shaft” Protected

in until byflush.
– Install connecting bolts of housing halves at clutch end.

Tightening torque
Steel bolts: 20 Nm + 45°
Aluminium screws: 10 Nm + 90°

– Fit drain plug.
– Install oil seals of input shafts ⇒ page 68 .

If large oil seal has already been renewed, you do not need to
renew it again.
– Install parking lock.

– Install new bolts.
Tightening torque
30 Nm.
– Install mechatronic unit ⇒ page 134 .
– Install flange shafts or stub shafts, installing new sealing rings
as you do so ⇒ page 294 .
– Install dual clutch ⇒ page 34 .

– Fill 1.7 litres of oil through parking lock.
– Install lever and cover.
– Fit cable support bracket.

Tightening torque:
8 Nm.


– Refit both caps of the ventilation -arrow-.

– Re-installing the breather hose:
♦ Leon 2009 ► ⇒ page 149
– Take gearbox off assembly stand.
Assembly of gearbox is completed.

4 Dismantling and assembling gearbox housing
1 - Gearbox
❑ With oil guide
⇒ page 221
2 - Retainer washer
❑ Smooth side faces out‐
wards
3 - Differential shim
❑ Determining thickness
⇒ page 271
4 - Differential bearing race
❑ Driving out ⇒ page 222
❑ Insertion ⇒ page 223 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Output shaft shim 3 respect to the correctness of information in this document. Copyright by SEAT S.A.
⇒ page 271
6 - Output shaft bearing race 3
❑ Remove ⇒ page 221
❑ Preparing for pressing
in ⇒ page 222
❑ Insertion ⇒ page 222
7 - Output shaft shim 2
⇒ page 271
❑ Preparing for pressing
in ⇒ page 222
⇒ page 271
11 - Bearing for the inner input shaft
❑ Remove to press out retaining ring
❑ Press in »new« bearing ⇒ page 221
12 - Securing ring
❑ Always replace

Press in bearing for inner input shaft

– Drive in the bearing to the end.
– Install »new« retaining ring.
Installation position of oil guide in gearbox housing

– Oil guide is clipped into housing.
Pull out bearing races of output shafts

All bearing races of output shafts 1 to 3 are removed »in the same
way«. Here, for example, the removal of output shaft 1 is descri‐
bed. Bearing races of output shafts 2 and 3 are removed in the
same manner.
– Make sure that bearing race does not »get stuck« on supports
of puller.
Pressing in output shaft bearing race 1

– Insert shim.
– Press in bearing race to stop.
4. Dismantling and assembling gearbox housing 221

Prepare bearing races of output shafts 2 and 3 for pressing in

– First insert 1 shim into housing.
– Then position »correct« bearing race and drive bearing race
in using targeted, light taps until it can no longer drop out.
– Fit spacer sleeve - T10428- and press tool - VW 402- onto

press.
Pressing in bearing races of output shafts 2 and 3

This shows how bearings of output shaft 2 are pressed in.
-A- Output shaft bearing race 2
-B- Output shaft bearing race 3
– To press in bearing of output shaft 3, place housing on thrust
piece -B-.
Driving out bearing race of differential

Bearing is driven out using a suitable drift.
– Before driving out, place ring of thrust pieces for drive pinion
bearing - VW 470- under bearing.
– To prevent gearbox housing from rocking, also insert wedge -
T10357- under housing.

Pressing in bearing race of differential

A second mechanic is required for driving in.
– Place thrust piece - T10380- on edge of workbench. Position
gearbox housing with area of bearing point on thrust piece,
and hold housing firmly like that.
– A second mechanic inserts the oil ring and the shim. 2. Fitter
drives bearing in up to stop.
4. Dismantling and assembling gearbox housing 223

5 Dismantling and assembling clutch housing
1 - clutch housing
❑ Remove outer input
shaft ⇒ page 202
2 - Retainer washer
❑ Smooth side faces out‐
wards
3 - Fixed washer
❑ 0.65 mm thick
❑ Use from production
date 06/2011
4 - Differential bearing race
⇒ page 258
6 - Oil deflector
❑ Always renew a de‐
formed plate
❑ Protected
Preparing for pressing
in ⇒ unless
permitted pageauthorised
225 by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Pressing in output shaft
3 ⇒ page 225
⇒ page 258
❑ Preparing for pressing in ⇒ page 226
❑ Determining thickness ⇒ page 258
❑ Preparing for pressing in ⇒ page 225
❑ Pressing in output shaft 2 ⇒ page 225
12 - Outer input shaft
❑ Dismantling and assembling ⇒ page 228 .
13 - Centring sleeve
❑ 2 off

Preparing output shaft bearing race 2 for pressing in

– First place installing tool - T 10428- on the press bed.
– Insert shim and oil deflector.
– Carefully drive bearing shell in with a drift until it no longer falls
out.

– Place clutch housing »wrong way round« on drift - T10428- .
Use installing sleeve - VW 455- so that press pressure will be
applied to clutch housing in a controlled manner.

– Insert oil deflector first.
A shim is located under the bearing.
Driving out bearing race of differential

5. Dismantling and assembling clutch housing 225

– Bearing is driven out using a suitable drift.

In doing so the retaining plate is destroyed and must be renewed.
WARNING
In gearboxes from production date 06/2011 onward a fixed

washer with a thickness of 0.65 mm is installed between the
retaining plate and the bearing shell. If fitted, this fixed washer
must be inserted into the same position before pressing in the
bearing shell.
Pressing in bearing race of differential
Pulling out output shaft bearing race 1

Preparing output shaft bearing race 1 for pressing in
– First place tube - VW 415 A- under bearing seat.

This illustration show view »from below«. This means press pres‐
sure is not applied to clutch housing in an uncontrolled manner,
but is absorbed by tube.


– Insert calculated shim if you already know its thickness.
Pull out output shaft bearing race 2 and 3

It may be that oil deflectors get in the way when internal puller is
being put on. Carefully knock down guide plates with a hammer.
Plates deformed in this way must be renewed during installation.
5. Dismantling and assembling clutch housing 227

6 Dismantling and assembling outer in‐

put shaft
Overview
1- Outer input shaft
2- Retaining plate with bolts: the lettering faces towards the
gears, the smooth surface to the bearing
3- Bearing: pressing off ⇒ page 228 ; pressing on
⇒ page 228
4- Determining thickness of retaining ring ⇒ page 228
Outer input shaft - pressing off bearing

The bearing is destroyed during pressing off and must be re‐
newed.
Outer input shaft - pressing on new bearing to stop

– Make sure that bearing is only pressed on over inner ring.
• Lettering on plate faces towards gears.
Installing retaining ring

Objective is to secure bearing with retaining ring without play. To
achieve this, you must select ring that fits into groove without play.
– Insert rings one after another sideways into groove.
– Select ring that is just small enough to still be installed.

– Check that ring is located »correctly« in groove.
6. Dismantling and assembling outer input shaft 229

7 Dismantling and assembling inner input

shaft
Overview: inner input shaft
1- Input shaft on the inside
2- Synchromeshed gear for 5th gear: must not be pressed off
for cleaning. Pressing off ⇒ page 231 ; pressing on
⇒ page 231
3- Sensor wheel: must not be removed for cleaning Lever off
with lever; pressing on ⇒ page 232 . Always renew removed
sensor rings.
4- Synchromeshed gear for 3rd gear: pressing off
⇒ page 231 ; pressing on ⇒ page 231
5- Mobile pinion of 7th gear: press off ⇒ page 230 ; press on
⇒ page 230
6- Securing ring
7- Needle cage
8- Needle cage; »large« needles
9- Roller cage
Pressing off gear wheel for 7th gear
Pressing on gear wheel for 7th gear

– Carefully press on to stop.

Pressing off 3rd gear wheel
Pressing on gear wheel for 3rd gear

Pressing off 5th gear wheel

Pressing on 5th gear wheel

– Heat to 140 °C to press on.
– Align tube - 2040- on thrust plate - VW 401- so that shaft can
be pushed through downwards without »bumping«.
Use thrust plate - VW 402- to provide a secure hold for tube.
7. 231
Drive sensor ring onto »cooled« gear wheel for 5th gear

8 Output shaft 1: disassembling and

assembling, assembly overview
⇒ “8.1 Dismantling output shaft 1 partially”, page 234
⇒ “8.2 Dismantling output shaft 1 completely”, page 235
⇒ “8.3 Assembling output shaft 1”, page 237
⇒ “8.4 Dismantling and assembling locking collars and synchro-
hubs of output shaft 1”, page 243
1 - Output shaft 1
2 - Gear needle roller bearing
3 - Synchromeshed gear for
2nd gear
4 - Synchroniser ring
5 - Outer race
7 - Locking collar and synchro-
hub for 2nd and 4th gears
❑ Dismantling and assem‐
bling ⇒ page 243 .
9 - Outer race permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
12 - Needle bearing bush
13 - Mobile pinion of 4th gear
14 - Packing plate
Note
Output shaft is assembled as far as

this washer for purpose of adjusting
shaft.

17 - Synchromeshed gear for
3rd gear
19 - Outer race
21 - Locking collar and synchro-hub for 1st and 3rd gears
❑ Dismantling and assembling ⇒ page 243 .
8. Output shaft 1: disassembling and assembling, assembly overview 233

23 - Outer race
27 - Synchromeshed gear for 1st gear
28 - Attack washer
29 - Bearing
Note
Always renew the bearings on a

shaft together.
30 - Bolt
❑ Fitting ⇒ page 237
31 - Bearing cap
• Bearing races are not allowed to be swapped over. They are paired with the bearing.
32 - Bearing cap
• Bearing races are not allowed to be swapped over. They
Protected are paired
by copyright. with
Copying for the
private bearing.purposes, in part or in whole, is not
or commercial
33 - Bearing respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Driving in ⇒ page 237
Note

shaft together.
8.1 Dismantling output shaft 1 partially

Output shaft 1 only needs to be dismantled partially in order to
adjust gearbox.
Dismantle output shaft completely if gearbox is to be cleaned or
if parts of shaft are to be renewed ⇒ page 235 .
– Insert protective jaws into vice and clamp output shaft tight.
– Loosen and remove bolt with socket - T10061- .
Special wrench - T10035- can also be used.
Always renew bolt after removal.
Note
Lay suitable means under the press to ensure that the shaft does
not fall out underneath during pressing. It is also possible to hold
shaft by hand.

– Press selector gear 1st gear with bearing off output shaft.
– Driving out needle bearing
The sleeve of the needle bearing is pressed off with it in the next
step.
– Press selector gear 3rd gear with locking collar and synchro-
hub off the output shaft.
Assembling output shaft 1 ⇒ page 237 .
8.2 Dismantling output shaft 1 completely

Note
shaft by hand.

– Press selector gear 1st gear with bearing off output shaft.
step.
– Press selector gear 3rd gear with locking collar and synchro-
hub off the output shaft.
– Press out output shaft completely.
Note
Only carry out the following operation if the bearings are renewed.

Press off bearing of output shaft 1.

– Destroy cage of bearing first.
– Press off bearing inner race.
Press on bearing of output shaft 1.

Assembling output shaft 1 ⇒ page 237 .
8.3 Assembling output shaft 1

During this procedure, it can be seen how the output shaft 1 is
assembled. During the following work that is performed in the
press, make sure that the shaft bearing is not damaged.
If bearing is not going to be renewed then it must be protected.

• If bearing is pressed on, thrust plate - VW 447 i- must also be

used for each pressing operation.
• Pressing off bearing: ⇒ page 237
• Pressing on bearing: ⇒ page 237
– Place needle bearing onto output shaft.

– Make sure that cage is not broken.
– Wet bearing with oil.
– Place mobile pinion of 2nd gear onto the needle cage.

– Wet friction surfaces with oil.
– Fit both synchro-rings with outer race onto synchromeshed
gear for 2nd gear.
– Put on locking collar with synchro-hub. Make sure groove for
selector fork is pointing »upwards«, and collar of locking collar
»downwards«.
Synchro-hub can only be put in place. It is pressed on in next step.

– Press on synchro-hub.
Note
♦ Bear two things in mind when pressing:

♦ Raise gear wheel and turn it at same time. This allows syn‐
chro-ring to locate its installation position before ring is clam‐
ped by synchro-hub.
♦ Once the ring has found it's seat, only continue pressing until
an increased force is felt. Then stop pressing immediately.
Synchromeshed gear for 2nd gear must have axial play. Gear
has reached its installation position as soon as force during
pressing rises. If you continue pressing then you will be press‐
ing synchro-hub against needle bearing, thus damaging it.
After pressing, gear wheel must turn »freely« when shaft is in

horizontal position.
– Press on sleeve for needle bearing of synchromeshed gear for

4th gear.
Installation direction: the lettering must face »downwards«.
Note
Here also stop pressing immediately whenProtected

you notice a rise
by copyright. in for private or commercial purposes, in part or in whole, is not
Copying
force during pressing. Do not continue pressing!
– Fit needle bearing.

– Wet friction surfaces with oil.
– Put on large synchro-ring, outer ring and small synchro-ring.

– Put on synchromeshed gear for 4th gear.
– Press on washer.
Note
♦ Here also stop pressing immediately when you notice a rise in

♦ After pressing, gear wheel must turn »freely« when shaft is in
♦ Output shaft is assembled as far as this washer for purpose of
adjusting shaft.
WARNING respect to the correctness of information in this document. Copyright by SEAT S.A.
Do not assemble output shaft further until the gearbox has

been adjusted. ⇒ page 257 .

3rd gear.
Note
Here also stop pressing immediately when you notice a rise in



– Wet bearing and friction surfaces with oil.
– Put on synchromeshed gear for 3rd gear, small synchro-ring,
outer ring and large synchro-ring.
– Press on locking collar and synchro-hub.
Note

ped by synchro-hub.
Synchromeshed gear for 3rd gear must have axial play. Gear
pressing rises. Continuing to press will force synchro-hub
against needle bearing and damage it.

– Press onunless
permitted sleeve for needle
authorised bearing
by SEAT S.A. SEAT S.A ofdoes
synchromeshed gear
not guarantee or accept for with
any liability
1st gear.
Note



– First place small synchro-ring onto synchromeshed gear for
1st gear.
– Then outer ring and then large synchro-ring.
Gear wheel and rings can be placed on shaft together.
– Press on washer.
Note


– Press on bearing.
Note

– Tighten new bolt.

Special wrench - T10035- can also be used for tightening.

8.4 Dismantling and assembling locking col‐

lars and synchro-hubs of output shaft 1
Note
Before dismantling mark the installed position and relationship of

all parts to each other.
Dismantling and assembling 2nd and 4th gear locking collar and
synchro-hub
Lettered side of synchro-hub faces groove in locking collar.
Locking collar of 3rd and 1st gear is assembled accordingly. It is
symmetrical, it does not have a particular installation direction.

9 Output shaft 2: disassembly and as‐

sembly, assembly overview
⇒ “9.1 Dismantling output shaft 2”, page 245
⇒ “9.3 Dismantling and assembling locking collars and synchro-
hubs of output shaft 2”, page 251
1 - Output shaft 2
2 - Needle thrust bearing
4 - Reverse gear pinion
5 - Packing plate
hub for 6th gear
9 - Needle bearing bush permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
10 - 6th speed selector gear
11 - Packing plate
Note
Output shaft is assembled as far as

this washer for purpose of adjusting
shaft.

14 - 7th gear mobile pinion
16 - Locking collar and syn‐
chro-hub for 5th and 7th gears
20 - Mobile pinion of 5th gear
21 - Bearing
Note

shaft together.
22 - Bolt

❑ Fitting ⇒ page 247

❑ 60 Nm, 90° further.
23 - Bearing cap
24 - Bearing cap
25 - Bearing

shaft together.
9.1 Dismantling output shaft 2

Note
shaft by hand.
– Press selector gear 5th gear with bearing off output shaft.
step.
9. Output shaft 2: disassembly and assembly, assembly overview 245

– Press out output shaft completely.
Note

Note
shaft by hand.


– Assembling output shaft 2 ⇒ page 247 .

assembled. During theProtected
following workCopying
by copyright. that isforperformed in the
private or commercial purposes, in part or in whole, is not
press, make sure that the shaft
permitted bearingbyisSEAT
unless authorised notS.A.damaged.
SEAT S.A does not guarantee or accept any liability with
• If bearing is pressed on, thrust plate - VW 447 H- must also be
• Pressing on bearing: ⇒ page 247
– Place both needle bearings onto output shaft.
– Make sure that cages are not broken.
– Fit reverse gear wheel.
– Put on reverse gear wheel, axial bearing »with smooth side

facing upwards«.
– Put on locking collar with synchro-hub. Make sure circumfer‐
ential edge of sleeve is pointing »upwards«, and collar of
locking collar »downwards«.
Dismantling and assembling locking collar ⇒ page 251 .

Note
Stop pressing immediately when you notice a rise in force during

pressing. Do not continue pressing!
– Press on sleeve for synchromeshed gear for 6th gear.
– Put on synchro-ring, needle bearing and synchromeshed gear

for 6th gear.
– Press on washer for synchromeshed gear for 6th gear.

If this washer has lettering then position this side of washer
»downwards«.
Note
♦ Here also stop pressing immediately when you notice a rise in

♦ Output shaft is assembled as far as this washer for purpose of
adjusting shaft.
WARNING
Do not assemble output shaft further until the gearbox has

been adjusted. ⇒ page 257 .


7th gear.
Note

– Put on needle bearing, synchromeshed gear for 7th gear and

synchro-ring.
– Wet bearing and friction surface with oil.
– Put on locking collar with synchro-hub. Make sure circumfer‐
ential edge of sleeve is pointing »upwards«, and collar of
locking collar »downwards«.
Note

ped by synchro-hub.
Synchromeshed gear for 3rd gear must have axial play. Gear
pressing rises. Continuing to press will force synchro-hub
against needle bearing and damage it.


5th gear.
Note

– Put on synchro-ring, needle bearing and gear wheel for 5th

gear.
– Wet bearing and friction surface with oil.
– Press on bearing.
– Install and tighten new bolts.

Tightening torque ⇒ page 244
Special wrench - T10035- can also be used for tightening.


lars and synchro-hubs of output shaft 2
Note

Locking collar and synchro-hub for synchromeshed gear for 6th

gear
Locking collar and synchro-hub for synchromeshed gear for 7th

and 5th gears

10 Output shaft 3: disassembly and as‐

sembly, assembly overview
⇒ “10.1 Dismantling output shaft 3”, page 253
⇒ “10.3 Dismantling and assembling locking collar and synchro-
hub of output shaft 3”, page 256
1 - Output shaft 3
3 - Reverse gear synchro‐
meshed gear
hub for reverse gear
6 - Securing ring
7 - Stop ring
8 - Parking lock gear
❑ The smooth side points
to the end of the shaft,
the »bulged« side to the
mobile pinion of the re‐
verse gear.
9 - Bearing
10 - Bearing cap
⇒ page 220
• Bearing races are not al‐
lowed to be swapped over.
They are paired with the
bearing.
11 - Bearing cap
⇒ page 224
• Bearing races are not al‐
lowed to be swapped over.

They are paired with the

bearing.
12 - Sleeve
❑ Removal is not mandatory
❑ Lift out with screwdriver
❑ Press in by hand using locking pin - T10043- to stop
13 - Bearing

10.1 Dismantling output shaft 3
Note
shaft by hand.
– Press off parking lock gear together with bearing.
– Remove the safety ring.
– Press out shaft.
Note

Note
shaft by hand.


– Assembling output shaft 3 ⇒ page 254 .

assembled. During the following work that is performed in the
press, make sure that the shaft bearing is not damaged.
• If bearing is pressed on, thrust plate - VW 447 H- must also be
• Pressing on bearing: ⇒ page 254 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Wet bearing slightly with oil.

– Put on reverse gear synchromeshed gear, synchro-ring and

locking collar.
– Wet friction surface with oil.
– Press on synchro-hub and locking collar.
Note

ped by synchro-hub.
– Fit the securing ring.

– Insert -stop ring-.
– Put on parking lock gear and bearing.

– Press on both together.


lar and synchro-hub of output shaft 3
Note

Dismantling and assembling locking collar and synchro-hub of

output shaft 3

11 Notes on gearbox adjustment

⇒ “11.1 Calculating shims for clutch housing”, page 258
Adjustment work is divided into 2 »sections«:
A - This involves finding shims

that are inserted into clutch
housing.
❑ This is the start of the
work. Objective is to
align output shafts 1 to 3
in clutch housing »in
one imaginary plane«.
This »imaginary plane«
is defined by face end of
outer input shaft. For
this procedure, refer to
chapter ⇒ page 258 .
A fixed washer is inserted un‐ permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
der the bearing shell of the dif‐ respect to the correctness of information in this document. Copyright by SEAT S.A.
ferential from production date

06/2011 which is not shown
here but which if fitted is to be
installed together with the
bearing shell.
B - During assembly of gear‐

box, »thickness« of these
shims determines force with
which shafts are »clamped«
between both halves. These
shims are inserted in gearbox
housing.
❑ For this procedure, refer
to ⇒ page 271
• Only once correct shims
-A- have been calculated
for clutch housing, or if
there is no need for meas‐
urement, can shims -B- be
determined.
• Therefore, do not calculate
shims -B- until shims -A-
are OK.
• Work with intact tools, make sure the workplace is clean.

• Avoid temperature differences between gearbox and adjusting
tool.
• Flange surfaces of both housing halves should be smooth and
neither »indented nor damaged«.
• Do not put on measuring table unless there are guide bushes
in housing.
• Do not swap over bearing races of same size, always renew
bearings on a shaft jointly.
• Follow this procedure step by step. Temperature differences,
such as between »summer and winter«, affect all measuring
tools that are used.
• Numbers given in the calculations below are in millimetres.
»Your measuring tools« and »dimensions on your gearbox«
11. Notes on gearbox adjustment 257

will differ from the values stated here. These numerical values
always have a remark used for identifying -Example-.
• Notes made during measurements should be legible and easy
to follow. Oily pieces of paper are not appropriate for this.
11.1 Calculating shims for clutch housing

♦ Measuring tool - T10425-
♦ Dial gauge - VAS 6079-
♦ Universal bracket for gauge - VW 387-
♦ Not shown: Depth gauge, digital 200 mm with measuring hook

- VAS 6619-
Brief description:
This »section« explains how to calculate thickness of shims in
clutch housing. 3 shims are installed in total. One shim under each
secondary shaft. Differential does not have a shim here.

This is the start of the work. Objective is to align output shafts 1

to 3 in clutch housing »in one imaginary plane«. This »imaginary
plane« is defined by face end of outer input shaft.
Oil deflectors are inserted under output shafts 2 and 3, which are
not shown here. For information about installation of shims, oil
deflectors and bearing races, refer to ⇒ page 224 .
Note respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ Do not install any oil deflectors or shims when calculating which shims to use. Only install bearing races of
shafts.
♦ A fixed washer is inserted under the bearing shell of the differential from production date 06/2011 which is
not shown here but which if fitted is to be installed together with the bearing shell.

Prerequisite:
• The sealing surface of the clutch housing is clean, flat and not
»broken or damaged«.
• Outer input shaft is installed ⇒ page 224 .
• Bearing races of all shafts and bearing race of differential are
installed ⇒ page 224 .
• No oil deflector and no shim is installed.
Note
Only for carrying out the adjustment : do not install any shim. Do
not install any oil deflectors.
– Place partially dismantled output shaft 1 and output shaft 2 into

bearing race.
To find out how »far« shafts are allowed to be assembled, refer
to ⇒ page 234 for output shaft 1, and ⇒ page 247 for output shaft
2.
– Make sure that dowel sleeves are inserted in clutch housing.

Assemble measuring tool - T10425- for work on clutch housing.

– Place measuring
the correctnesstool - T10425- on dowel sleeves.
respect to of information in this document. Copyright by SEAT S.A.
– Place mandrel - T10425/3- on output shaft 1.
Note
All mobile pinions have a burr on their teeth. This burr »disturbs«
when measuring. This is intended to show -where- gear wheels
are measured in following measurements.
Measuring surfaces start at »roots« of teeth.

They extend as far as »first shoulder«. Shown here in “light” col‐
our in illustration.
Teeth themselves can be used for measurement. It is important
to make sure that depth gauge does not locate on burrs.
Start with output shaft 1.

– Zero depth gauge - VAS 6619- on outer input shaft. Shown

here in »green«. Set depth gauge to »0«.
– Use the depth gauge - VAS 6619- to measure to the mobile

pinion of 4th gear of the secondary shaft. Shown here in
»blue«.
– Make a note of this value.
– Call this value “A1a”.

– Three measurements are taken. Call the additional values

“A1b” and “A1c”.
– Before turning further mark the drive shaft.
– Continue to Turn drive shaft further by 120° in
-the direction of the arrow- and measure again. Then turn
through another 120° and measure again.
Note
Gears of shafts have helical gearing. It is possible for shafts to be

raised out of their bearing when they are turned.
– To ensure that the shafts remain in the bearing during turning

keep one hand firmly pressed on the mandrel - T10425/3- . Do
not forget headpiece - T10425/5- .
Calculate the mean value from the three measurements “A1a”,
Formula: A1a + A1b + A1c 3 = A1
Gear wheel for 4th gear has axial play on shaft. This play is
measured as follows:

– Bolt a universal dial gauge bracket - VW 387- to the sealing

surface of the clutch housing.
– Place the dial gauge - VAS 6079- onto the gear wheel of the
4th gear.
– Adjust dial gauge with pre-tension to »0«.
– Raise 4th gear wheel to stop and record the resulting meas‐
urement.
– Call this value “B1”.
– Calculation: “A1” minus “B1” = calculated shim thickness.
Calculated shim thickness Shim to be installed (in milli‐
metres)
from to
0,625 0,674 0,65
0,675 0,724 0,70
0,725 0,774 0,75
0775 0,824 0,80
0,825 0,874 0,85
0,875 0,924 0,90
0,925 0,974 0,95
0,975 1,024 1,00
1,025 1,074 1,05
1,075 1,124 1,10
1,125 1,174 1,15
1,175 1,224 1,20
1,225 1,274 1,25
1,275 1,324 1,30
1,325 1,374 1,35
1,375 1,424 1,40
1,425 1,474 1,45
1,475 1,524 1,50
1,525 1,574 1,55
1,575 1,624 1,60
1,625 1,674 1,65
1,675 1,724 1,70
1,725 1,774 1,75
– From the supplied shims, select the one that is required.
WARNING
Later in, only this shim must be inserted. Not 2.
Keep this shim carefully, do not mix it up with any other shims.
Continue with output shaft
Protected by 2.

– Place mandrel - T10425/3- on output shaft 2.

Turn mark on outer input shaft »into alignment« with output shaft
2.
Note


– Zero depth gauge - VAS 6619- on outer input shaft. Shown

here in »green«. Set depth gauge to »0«.
– Use the depth gauge - VAS 6619- to measure to the mobile

pinion of 6th gear of the secondary shaft 2. Shown here in
»red«.
– Make a note of this value.
– Call this value “A2”.

– Three measurements are taken. Call the additional values

Use »existing« mark for orientation.
– Continue to Turn drive shaft further by 120° in
-the direction of the arrow- and measure again. Then turn
through another 120° and measure again.
Note


Calculate the mean value from the three measurements “A2a”,
Formula: A2a + A2b + A2c 3 = A2
Gear wheel for 6th gear has axial play on shaft. This play is
measured as follows:

– Bolt a universal dial gauge bracket - VW 387- to the sealing

surface of the clutch housing.
– Place probe of the dial gauge - VAS 6079- on the 6th gear
wheel.
– Adjust dial gauge with pre-tension to »0«.
– Raise 6th gear wheel to stop and record the resulting meas‐
urement.
– Call this value “B2”.
– Calculation: “A2” minus “B2” = calculated shim thickness.
metres)
from to
0,625 0,674 0,65
0,675 0,724 0,70
0,725 0,774 0,75
0775 0,824 0,80
0,825 0,874 0,85
0,875 0,924
permitted unless authorised by SEAT S.A. SEAT S.A 0,90
does not guarantee or accept any liability with
0,925 0,974 0,95
0,975 1,024 1,00
1,025 1,074 1,05
1,075 1,124 1,10
1,125 1,174 1,15
1,175 1,224 1,20
1,225 1,274 1,25
1,275 1,324 1,30
1,325 1,374 1,35
1,375 1,424 1,40
1,425 1,474 1,45
1,475 1,524 1,50
1,525 1,574 1,55
1,575 1,624 1,60
1,625 1,674 1,65
1,675 1,724 1,70
1,725 1,774 1,75
1,775 1,824 1,80
1,825 1,874 1,85
1,875 1,924 1,90

– From the shims that have been supplied, measure shim that
you require.
WARNING
Keep this shim carefully, do not mix it up with any other shims.
– Remove output shafts 1 and 2 and assemble them.
♦ Output shaft 1 ⇒ page 237
♦ Output shaft 2 ⇒ page 247
♦ Then adjust output shaft 3.
– First measure thickness of synchromeshed gear for reverse

gear.
Note
When measuring ensure that measurements are not taken on the

burrs of the teeth.
– Make a note of this value and call it “B”.

Adjust output shaft 3.

Output shaft 3 is set correctly when dimension -K- = 19.9 milli‐
metres.
– Place output shaft 3 into bearing.

– Take bearing race that is to be installed and place onto shaft.

– Place mandrel - T10425/3- onto shaft.
– Zero depth gauge - VAS 6594- on synchromeshed gear for

reverse gear.
Note
When measuring ensure that measurements are not taken on the

burrs of the teeth.
– Measure distance from housing flange surface.

– Record this value and call it “A3”.
– Now, in order to determine which shim is used, from the value
“A3” the »thickness« of the selector gear for reverse gear “B3
is subtracted.” Call this value “C”.
Formula: “A3” minus “B3” = “C”

As a reminder: Output shaft 3 is set correctly when dimension

-K- = 19.9 millimetres.
– Therefore, now calculate a shim to arrive at -K- = 19.9 milli‐
metres.
The thickness of the shim to be installed is calculated from di‐
mensions -K- and “C” by the following method.
Formula: 19.9 millimetres minus value for “C” = calculated
shim thickness.
metres)
from to
0,775 0,824 0,80
0,825 0,874 0,85
0,875 0,924 0,90
0,925 0,974 0,95
0,975 1,024 1,00
1,025 1,074 1,05
1,075 1,124 1,10
1,125 1,174 1,15
1,175 1,224 1,20
1,225 1,274 1,25
1,275 1,324 1,30
1,325 1,374 1,35
1,375 1,424 1,40
1,425 1,474 1,45
1,475 1,524 1,50
1,525 1,574 1,55
WARNING
1- Keep this measured shim carefully, do not mix it up with any

other shims.
2- Place measuring tool - T10425- to one side.
3- Install measured shims for output shafts, bearing races and
oil deflectors ⇒ page 224 .
4- Assembling output shaft 1 ⇒ page 237 .
5- Assembling output shaft 2 ⇒ page 247 .
6- Insert all output shafts in clutch housing.
7- Put measuring tool - T10425- back onto clutch housing.
– Calculating shims for gearbox housing ⇒ page 271 .

12 Calculating shims for gearbox hous‐

ing
♦ Measuring tool - T10425-
♦ Not shown: Depth gauge, digital 300 mm - VAS 6594-

Brief description:
This »section« explains how to calculate thickness of shims in
gearbox housing. 4 shims are installed in total. One shim on each
secondary shaft. Differential does not have a shim here either.
12. Calculating shims for gearbox housing 271

Procedure:
First calculate how »high« shafts stand in clutch housing.
Then measure how »deep« gearbox housing is.
Subtract both »heights« from one another.
Bearing preload is stated for each shaft in working procedure.
Therefore, follow this procedure exactly, please.
Each shaft has a different preload, therefore follow the instruction
precisely and note the different preloads.
The correct shim can then be calculated in each case.
For information about installation of shims and bearing races after
»calculation«, refer to ⇒ page 220 .
ComplyProtected
with following
by copyright.work
Copyinginstructions:
– Measurerespect
height
to theof your mandrel
correctness - T10425/3-
of information in this document.. Copyright by SEAT S.A.

– Zero depth gauge - VAS 6594- on shoulder for bearing races.
– Measure height of mandrel.

Make a note of your mandrel height. Its height is needed in sub‐
sequent calculations. Identify height of mandrel as D=? mm.
Example: 230.03 mm
Note
Each mandrel has a different height. Therefore always measure

drift used.
Start with output shaft 1.
– Put on bearing race, mandrel and headpiece.

– Turn outer drive shaft. During turning press the mandrel firmly
downwards with one hand.
This locates output shaft 1 correctly in its bearing seat.
– Remove headpiece - T10425/5- from mandrel again and place
it to one side.

– Zero depth gauge - VAS 6594- on measuring tool - T10425- .

– Measure distance (height) from surface of measuring tool -
T10425- to flange surface of clutch housing.
Always measure close to the respective bearing position.

– Call this value “a1”.
– Note this value.
Example:
“a1” = 264.97 mm
– Measure distance (height) from mandrel to measuring tool -

T10425- .
– Call this value “b1”.
Example:
“b1” = 163.85 mm
It is calculated thus:
“a1” + “b1” minus height of mandrel “D” = height of output shaft
1
Example:
264.97 mm + 163.85 mm - 230.03 mm = 198.79 mm
– Note calculated result for “height of output shaft 1”.
Example: “height of output shaft 1” = 198.79 mm
You will require this value later.
Continue with output shaft 2.

– Put on bearing race which is to be installed, mandrel and

headpiece.
This locates output shaft 2 correctly in its bearing seat.
it to one side.

Always measure close tounless
permitted the authorised
respective bearing
by SEAT position.
S.A. SEAT S.A does not guarantee or accept any liability with
– Note down this value and call it “a2”.
Example:
“a2” = 264.93 mm


T10425- .
Example:
“b2” = 138.99 mm
2
Example:
264.93 mm + 138.99 mm - 230.03 mm = 173.89 mm
Continue with output shaft 3.
– Put on bearing race which is to be installed, mandrel and

headpiece.
This locates output shaft 3 correctly in its Protected
bearingbyseat.
it to one side.


Always measure close to the respective bearing position.

– Call this value “a3”.
Example:
“a3” = 264.92 mm

T10425- .
Example:
“b3” = 85.59 mm
3
Example:
264.92 mm + 85.59 mm - 230.03 mm = 120.48 mm
1- Place measuring tool - T10425- to one side.
2- Remove output shafts 1, 2 and 3
3- Install differential.
4- Put measuring tool - T10425- back onto clutch housing.
5- Place mandrel - T10425/3- with adapter - T10425/4- onto
measuring tool - T10425- .

– Zero depth gauge - VAS 6594- on shoulder for bearing race.

Make sure which is shoulder for bearing race.
– Measure height of mandrel - T10425/3- with adapter -

T10425/4- .
Record height of mandrel with adapter used. Its height is needed
in subsequent calculations. Call height of mandrel E=? mm.
Example: E = 256.00 mm
Note
Each mandrel responds to ambient temperature. Therefore

measure drift prior to each gearbox repair. When measuring,
make sure you are measuring the mandrel correctly. Depth gauge
should pass through mandrel and »contact« surface of measuring
tool. Mandrel has a shoulder at its »bottom end«. This shoulder
can lead to errors if care is not taken when measuring.
Always use guide pins - 3411- to install and remove differential.
– Put on bearing race, adapter, mandrel and headpiece.

– »Lightly« rotate the differential. During turning press the man‐
drel firmly downwards with one hand.
The differential will then seat correctly in its bearing seat.


– Call this value “a4a”.
Measure at 2 more points to keep inaccuracies as low as possible.
Call these values “a4b” and “a4c”
– Calculate average of these 3 measuring results.
Formula: a4a + a4b + a4c 3 = a4
Example:
“a4” = 264.96 mm + 264.98 mm + 264.94 mm3 = 264.96 mm
Resultant dimension “a4” = 264.96 mm


T10425- .
Example:
“b4” = 6.21 mm
“a4” + “b4” minus height of mandrel “E” = height of differential
Example:
264.96 mm + 6.21 mm - 256.00 mm = 15.17 mm
– Record the calculated value for the “height of the differential”.
Example: “height of differential” = 15.17 mm
This measurement calculates how »high« shafts stand in clutch
housing.
Subsequently, you will measure how »deep« gearbox housing is.
Adhere to following work procedures:
• The sealing surface of the clutch housing is clean, flat and not
»broken or damaged«. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Secure gearbox housing in a vice using support bridge -
T10323- .

– Insert dowel sleeves in gearbox housing.

– Set measuring tool on gearbox housing.
– Place measuring tool - T10425- on dowel sleeves.
Start again with measurements for output shaft 1:
The bearing pre-tension on this output shaft 1 is: 0.25 mm.
– Zero depth gauge - VAS 6594- on flange surface.
Note
When zeroing, press against leg of depth gauge -arrow-.

– Measure at seat of bearing race in gearbox housing.

– Note calculated result for “depth of output shaft 1”.
Example: “depth for output shaft 1” = 199.89 mm
Now value for “height of output shaft 1” is required.
– Complete following calculus: “depth for output shaft 1” minus
“height of output shaft 1” plus bearing preload 0.25 mm = cal‐
culated shim thickness
Example: “depth for output shaft 1” = 199.89 mm
199.89 mm - 198.79 mm + 0.25 mm = 1.35 mm
– Record the value for the “calculated shim thickness”.
Example: “calculated shim thickness” = 1.35 mm
Calculated shim thickness in Shim to be installed (in milli‐
gearbox housing for output shaft metres)
1
from to
0,625 0,674 0,65
0,675 0,724 0,70
0,725 0,774 0,75
0775 0,824 0,80
0,825 0,874 0,85
0,875 0,924 0,90
0,925 0,974 0,95
0,975 1,024 1,00
1,025 1,074 1,05
1,075 1,124 1,10
1,125 1,174 1,15
1,175 1,224 1,20
1,225 1,274 1,25
1,275 1,324 1,30
1,325 1,374 1,35
1,375 1,424 1,40
1,425 1,474 1,45
1,475 1,524 1,50
1,525
Protected by copyright. 1,574
Copying for private or commercial purposes,1,55
in part or in whole, is not
1,575 1,624
respect to the correctness 1,60by SEAT S.A.
of information in this document. Copyright
1,625 1,674 1,65

1,675 1,724 1,70
1,725 1,774 1,75
1,775 1,824 1,80
1,825 1,874 1,85

– From the shims that have been supplied, measure shim that
you require.
WARNING
Continue with measurements for output shaft 2:
Note
Press against leg of depth gauge -arrow-.


Example: “depth of output shaft 2” = 175.18 mm
175.18 mm - 173.89 mm + 0.30 mm = 1.59 mm
2
from to
0,625 0,674 0,65
0,675 0,724 0,70
0,725 0,774 0,75to the correctness of information in this document. Copyright by SEAT S.A.
respect
0775 0,824 0,80

0,825 0,874 0,85
0,875 0,924 0,90
0,925 0,974 0,95
0,975 1,024 1,00
1,025 1,074 1,05
1,075 1,124 1,10
1,125 1,174 1,15
1,175 1,224 1,20
1,225 1,274 1,25
1,275 1,324 1,30
1,325 1,374 1,35
1,375 1,424 1,40
1,425 1,474 1,45
1,475 1,524 1,50
1,525 1,574 1,55
1,575 1,624 1,60
1,625 1,674 1,65
1,675 1,724 1,70
1,725 1,774 1,75
1,775 1,824 1,80
1,825 1,874 1,85

WARNING
Continue with measurements for output shaft 3:

Note
When zeroing, press against leg of depth gauge -arrow-.


121.40 mm - 120.48 mm + 0.15 mm = 1.07 mm
3
from to
0,625 0,674 0,65

0,675 0,724 0,70
0,725 0,774 0,75
0775 0,824 0,80
0,825 0,874 0,85
0,875 0,924 0,90
0,925 0,974 0,95
0,975 1,024 1,00
1,025 1,074 1,05
1,075 1,124 1,10
1,125 1,174 1,15
1,175 1,224 1,20
1,225 1,274 1,25
1,275 1,324 1,30
1,325 1,374 1,35
1,375 1,424 1,40
1,425 1,474 1,45
1,475 1,524 1,50
1,525 1,574 1,55
1,575 1,624 1,60
1,625 1,674 1,65
1,675 1,724 1,70

WARNING
Continue with measurements for differential:
Bearing preload for differential is: 0.20 mm.

Remove measuring tool - T10425- .
Calculate depth of differential:
To measure depth of differential as accurately as possible, meas‐
ure at 3 points around bearing seat. »Average« the measurement
results.
– Place two gauge blocks - T40100- on flange surface.

The measurement is repeated at 2 other points -arrows- on the
flange surface, to reduce measurement inaccuracies.
– Measure 3 times around bearing seat -arrows-.

Please measure carefully.
– Make a note of average of these 3 measurements.
Example: 16.28 mm + 16.27 mm + 16.29 mm3 = 16.28 mm
Example: result of first measurement = 16.28 mm
Second measurement is taken:

– Place both gauge blocks - T40100- on flange surface.


Example: result of second measurement = 16.25 mm
Third measurement is taken:
– Place both gauge blocks - T40100- on flange surface.



Example: result of third measurement = 16.23 mm
Calculate average of all three measuring results.
Example: 16.28 mm + 16.25 mm + 16.23 mm3 = 16,253 mm
– Correct mathematical rounding: = 16.25 mm
– Note calculated result for “depth of output shaft”.
Example: “depth of differential” = 16.25 mm
Now value for “height of differential” is required.
– Calculate as follows: “depth for differential” minus “height of
differential” plus bearing preload 0.20 mm = calculated shim
thickness
Example: “height of differential” = 15.17 mm
Example: “depth of differential” = 16.25 mm
16.25 mm - 15.17 mm + 0.20 mm = 1.28 mm
Calculated shim thickness of dif‐ Shim to be installed (in milli‐
ferential metres)
from to
0,625 0,674 0,65
0,675 0,724 0,70
0,725 0,774 0,75
0775 0,824 0,80
0,825 0,874 0,85
0,875 0,924 0,90
0,925 0,974 0,95
0,975 1,024 1,00
1,025 1,074 1,05
1,075 1,124 1,10
1,125 1,174 1,15
1,175 1,224 1,20
1,225 1,274 1,25
1,275 1,324 1,30
1,325 1,374 1,35
1,375 1,424 1,40

WARNING
– Installing shims and bearing races of gearbox housing

⇒ page 220 .
– Assembling gearbox ⇒ page 209 .

13 Parking Lock
Overview: gearbox disassembly ⇒ page 200 .
Dismantling gearbox ⇒ page 202 .
Assembling gearbox ⇒ page 209 .
Information about selector lever cable:
⇒ “13.1 Removing and installing cover for parking lock”,
page 291
⇒ “13.2 Removing and installing parking lock”, page 292
13.1 Removing and installing cover for park‐

ing lock
♦ Lever for releasing - 80 - 200-
Removal:
• Gearbox in vehicle
• Selector lever in »P«.
Remove air filter housing.
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Using removal lever - 80 - 200- lever selector lever cable off
gearbox selector lever.
13. Parking Lock 291

– Unscrew bolt -3- and detach gearbox selector lever -4-.

– Remove bolt -2- and detach cover -1- for parking lock.
Installation
Cover for parking lock must be renewed if seal for selector shaft
or seal on cover for parking lock is leaking.
– Clean sealing surface and cover for parking lock -1-.
– Fit parking lock cover -1- and screw in bolts -2-.
– Fit gearbox selector lever -4- and screw in bolt -3-.
Perform remaining installation in reverse order of removal.
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
Install air cleaner housing.
Tightening torques
13.2 Removing and installing parking lock

♦ Socket and key - 3410-
Removal:
• Gearbox in vehicle
– Remove cover for parking lock -1- ⇒ page 291 .

– Remove bolts -2- and pull parking lock -1- off dowel sleeves
-arrows-.
If parking lock cannot be removed by hand:
– Apply multi-purpose tool - VW 771- with extractor tool - VW
771/37- behind parking lock and remove parking lock by pull‐
ing on alternate sides.
– Always renew bolts -2-.
Installation
– Fit parking lock -1- onto dowel sleeves -arrows-.
– Screw in new bolts -2-.
Tightening torque:
20 Nm, turn 90° further
– Install cover for parking lock -1- ⇒ page 291 .
13. Parking Lock 293

39 – Final drive - front differential

1 Oil seals
Gearbox identification ⇒ page 1 .
Code, engine allocation ⇒ page 3 .
Cleaning norms when working in the gearbox ⇒ page 13 .
Renew gear oil ⇒ page 194 .
⇒ “1.1 Renewing seal for right flange shaft”, page 294
⇒ “1.2 Renewing oil seal for left flange shaft”, page 296
1.1 Renewing seal for right flange shaft

Left ⇒ page 296 .

equipment required
♦ Thrust pad - 3305-
♦ Installation device -
T10038-
♦ Torque wrench -
V.A.G 1331- respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ Torque wrench -
V.A.G 1332-
294 Rep. gr.39 - Final drive - front differential

Removal:
Note
♦ Do not remove both drive shafts from the gearbox together.

One drive shaft must remain in place so the opposite wheel
can be held in position when removing or installing the bolts
into the stub shafts.
♦ Do not loosen both securing bolts in left and right flange shafts
at the same time. If the differential bevel gears turn it is very
difficult to reinstall the bolts.
♦ Remove drive shaft from gearbox and lay to side. Drive shaft
is fixed onto suspension strut with tensioning belt - T10038- .
♦ You do not need to remove the centre bolt of the drive shaft.
– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Noise insulation - exploded view .
– Remove drive shaft deflector cap from engine -arrows-, if fit‐

ted.
Unbolt drive shaft from gearbox.
– Tie-up drive shaft as high as possible. Do not damage paint
on drive shaft.
– Remove right flange shaft of gearbox.

– Pull out flange shaft.
– Pry seal out using assembly lever.
– Half-fill space between sealing lip and dust lip of new seal with
sealing grease .
1. Oil seals 295

– Fit a new seal as far as possible without tilting.

– Fit flanged shaft.
– Tighten new countersunk bolt to 30 Nm. When doing this,
press flange shaft against gearbox so that bolt engages in
thread.
– Fit drive shaft back on ⇒ Rep. gr. 40 ; Removing and installing
drive shafts .
– Renew gear oil ⇒ page 194 .
– Install noise insulation and tighten, tightening torques ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 50 ; Noise insulation -
exploded view .
1.2 Renewing oil seal for left flange shaft

Right side ⇒ page 294 .

equipment required
♦ Thrust pad - 3305-
♦ Installation device -
T10038-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-

Removal:
Note
♦ Do not remove both drive shafts from the gearbox together.

One drive shaft must remain in place so the opposite wheel
can be held in position when removing or installing the bolts
into the stub shafts.
♦ Do not loosen both securing bolts in left and right flange shafts
at the same time. If the differential bevel gears turn it is very
difficult to reinstall the bolts.
♦ Remove drive shaft from gearbox and lay to side. Drive shaft
is fixed onto suspension strut with tensioning belt - T10038- .
♦ You do not need to remove the centre bolt of the drive shaft.

exploded view .
– Remove left-hand wheel housing liner ⇒ Rep. gr. 66 ; Front
wheel housing liner - exploded view .
– If present: unbolt front left vehicle level sender - G78- from

suspension link.
Tightening torque ⇒ Rep. gr. 40 ; Sensor for front left-hand ve‐
hicle level sensor - G78- : removing and installing
– Disconnect left coupling rod from anti-roll bar ⇒ Rep. gr. 40 ;
Assembly overview - subframe, anti-roll bar, suspension links .
– Only unbolt left suspension link from suspension strut.

Remove drive shaft from gearbox ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Removing and installing drive
Protected shafts
by copyright. . for private or commercial purposes, in part or in whole, is not
Copying
– Swivel the left-hand drive shaft towards thetowheel
respect housing.
the correctness of information in this document. Copyright by SEAT S.A.
– Tie-up drive shaft as high as possible. Do not damage paint

on drive shaft.
1. Oil seals 297

– Remove left flange shaft of gearbox.

– Pull out flange shaft.
– Pry seal out using assembly lever.
– Half-fill space between sealing lip and dust lip of new seal with
sealing grease .
– Fit a new seal as far as possible without tilting.

– Fit flanged shaft.
– Tighten new countersunk bolt to 30 Nm. When doing this,
press flange shaft against gearbox so that bolt engages in
thread.
– Fit drive shaft back on ⇒ Rep. gr. 40 ; Removing and installing
drive shafts .
– Install transverse link and coupling rod again ⇒ Running gear,

axles, steering; Rep. gr. 40 ; Removing and installing drive
shafts .
– Renew gear oil ⇒ page 194 .
– Install noise insulation
Protected and
by copyright. tighten,
Copying tightening
for private torques
or commercial purposes,⇒in part
Gen‐ or in whole, is not
eral body repairs,
permitted unlessexterior; Rep.
authorised by SEAT gr. 50 ;S.A
S.A. SEAT Noise
does notinsulation -
exploded view . to the correctness of information in this document. Copyright by SEAT S.A.
respect

D3E801DDA08-7 Speed Dual Clutch Automatic Gearbox 0AM

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Service

Service Department. Technical Information

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Copyright © 2016 Seat S.A D3E801DDA08

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

KHN - Gearbox identification

2 Overview of the drive force

2 Rep. gr.00 - Technical data

3 Code, engine allocation

3.1 Ibiza 2008 ►, Ibiza ST 2010 ►

3.2 Altea 2009 ►, Altea XL 2009 ►,

3. Code, engine allocation 3

Dual clutch gearbox 0AM

3.3 Toledo 2013 ►

4 Rep. gr.00 - Technical data

Dual clutch gearbox 0AM

3. Code, engine allocation 5

Lubricant Gearbox oil for dual clutch gearbox 0AM

Filling quantity Hydraulic oil section in the mechatronic unit

Risk of damage to the gearbox.

6 Rep. gr.00 - Technical data

5 General repair instructions

5. General repair instructions 7

– Cover the hole with a cloth before installation work.

8 Rep. gr.00 - Technical data

In some vehicles, a cover is fitted over the engaging levers.

Several vehicles have a breather hose mounted on the Mecha‐

♦ Ibiza 2008 ►, Ibiza ST 2010 ► ⇒ page 148

5.3 Antifriction bearings

Be careful when working with oil. Dispose of drained oil prop‐

5.5 O-rings, oil seals and gaskets

5. General repair instructions 9

♦ After removing gaskets, check the contact surfaces of the cas‐

5.6 Safety locks

5.7 Bolts, nuts

♦ Renew self-locking nut.

5.8 Working with tester

10 Rep. gr.00 - Technical data

5.8.1 Read out the measurement value before

5.8.2 Complete basic setting

Do not carry out basic adjustment without a reason unless re‐

♦ when this is requested in the “Guided Fault Finding”,

5.8.3 Removal position, basic setting

5.9 Information on removing and installing

5. General repair instructions 11

5.10 Safety precautions

Accidents can be caused if the driver is distracted by test

Observe the following precautions to avoid possible injury and/or

Accidents and injury can be caused if a gear is inadvertently

Observe the following precautions to avoid possible injury and/or

When disconnecting the battery there is a risk of serious dam‐

♦ Always switch off the ignition before disconnecting the

– Disconnect battery ⇒ Rep. gr. 27 .

12 Rep. gr.00 - Technical data

5.11 Instructions for tow starts and when tow‐

Risk of irreparable damage to gearbox.

It is not possible to start the engine by means of tow-starting, for

5.12 Cleaning norms when working in the

5. General repair instructions 13

6 Safety measures for vehicles with

Risk of injury due to unintentional starting of the engine on ve‐

14 Rep. gr.00 - Technical data

1.1 Assembly overview - dual clutch, gear‐