S01BJXY8W20-5-Speed Manual Gearbox 02R

Service
Workshop Manual
Ibiza 2008 ➤
Ibiza ST 2010 ➤
Toledo 2013 ➤
5-speed manual gearbox 02R
Edition 05.2016
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 - 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 S01BJXY8W20

Ibiza 2008 ➤ , Ibiza ST 2010 ➤ , Toledo 2013 ➤
5-speed manual gearbox 02R - Edition 05.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Calculating overall gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Code, engine allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Ibiza 2008 ►, Ibiza ST 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Toledo 2013 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Filling quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1 Ibiza 2008 ►, Ibiza ST 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Toledo 2013 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.2 Gaskets, Protected
seals by. copyright.
. . . . . .Copying
. . . . for
. .private
. . . .or.commercial
. . . . . . purposes,
. . . . . in. .part
. .or. in. whole,
. . . .is. not
.................. 8
6.3 Sealant permitted
. . .respect
. unless
. . .to.authorised
. . correctness
the . . . by
. .SEAT
. of
. .information
. . . . . .in.this
. .document.
. . . . . .Copyright
. . . . .by. SEAT
. . . .S.A.
.....................
S.A. SEAT S.A does not guarantee or accept any liability with
8
6.4 Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.5 Bolts, nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.6 Antifriction bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.7 Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.8 Synchromesh rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.9 Gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.10 Mobile pinions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.11 Coupling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 Safety precautions for vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Clutch mechanism: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Clutch mechanism: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Removing and installing clutch pedal switch F36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Removing and installing mounting bracket with clutch master cylinder . . . . . . . . . . . . . . . . 16
1.5 Removing and installing clutch pedal with over-centre spring, left-hand drive vehicle . . . . 19
1.6 Removing and installing clutch pedal, left-hand drive vehicle . . . . . . . . . . . . . . . . . . . . . . 22
1.7 Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.8 Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.9 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.10 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.11 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Clutch release assembly: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3 Clutch: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1 Gear mechanism: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.1 Shifting: installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.2 Gear stick handle with cover - Installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.3 Removing and installing the gear stick handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.4 Gear selection mechanism:installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.5 Gear selection mechanism cables: removing and fitting; general overview . . . . . . . . . . . . 43
1.6 Gearbox mechanism: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.7 Gear drive mechanism: adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2 Gearbox : removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.1 Removing and installing the gearbox, Ibiza 2008 ►, Ibiza ST 2010 ► . . . . . . . . . . . . . . . . 53
Contents i
2.2 Removing and installing gearbox: Toledo 2013 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4 Gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.1 Check and refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.2 Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5 Gearbox: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.2 assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.3 Assembly overview - removing and installing cover for gearbox housing and 5th gear . . . . 85
5.4 Removing and installing gearbox housing and selector mechanism - Assembly overview
........................................................................ 86
5.5 Removing and installing input shaft, output shaft, differential and selector rods - Assembly
overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.6 Assembly sequence - removing and installing cover for gearbox housing and 5th gear . . 88
5.7 Assembly sequence - Dismantling and assembling gearbox completely . . . . . . . . . . . . . . 94
6 Gearbox casing and clutch housing: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7 Selector unit (gearbox side) disassembly and assembly (selector shaft can be removed from
the selector cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
8 Selector unit (gearbox side) disassembly and assembly (selector shaft cannot be removed
from the selector cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
9
Protected by Dismantling
copyright. Copying and assembling
for private or commercialselector
purposes, in forks . . . .is.not
part or in whole, ............................... 121
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

1 Input shaft: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

1.1 Disassembly and assembly of the input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.2 Input shaft: adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.1 Input shaft: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.2 Secondary shaft: adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3 Reverse gear shaft: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.1 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

1 Replace seals for flanged shafts with installed equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.2 Distinguishing seals for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.3 Renewing seal (two-part seal and sleeve for right flange shaft) . . . . . . . . . . . . . . . . . . . . . . 159
1.4 Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft) . . . . 162
2 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3 Differential assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.1 Differential: assembly and disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.2 Differential: Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
ii Contents
00 – Technical data
1 Gearbox identification
(ERL003121; Edition 05.2016)
⇒ “4 Code, engine allocation”, page 5 .
⇒ “5 Filling quantity”, page 7 .
Location on gearbox
Identification letters and date of manufacture -arrow 1-, type of
gearbox -arrow 2-.
Gearbox type
5-speed manual gearbox 02R -arrow 2-.
Engine code and manufacture date of gearbox

Example: EWR 11 09 1
I I I l
I I I l
Engine code Day Month Model year 2001
Additional data authorised
permitted unless dependbyon manufacture.
SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Note
The gearbox identification letters can also be found on the vehicle

data sticker.
1. Gearbox identification 1
2 Overview - power transmission

Identification
The -arrows- point forwards.
1 - Engine
2 - Coupling unit
3 - Manual gearbox housing
4 - Drive shaft
5 - Secondary shaft/pinion as‐
sembly
6 - Differential assembly
Ratio
Note
The -arrows- point forwards.
2 Rep. gr.00 - Technical data

I - 1. th gear
II - 2. th gear
III - 3. th gear
IV - 4. th gear
V - 5. gear
R - Reverse
A - Final group
T - Speedometer operation
In vehicles without ABS.
2. Overview - power transmission 3

3 Calculating overall gear ratio “i”

The gear ratio between two gears, is obtained by dividing the
number of teeth on the driven gear (Z2), by the number of teeth
on the driving gear (Z1).
Example:
Gears 5. gear Final group
driving gear (pri‐ 45 (Z1 = driving gear) 19 (Z1 = driving gear)
mary)
driving gear 34 (Z2 = driving gear) 60 (Z2 = driving gear)
(secondary)
i = Z2 : Z1 1)
In this way we can find out:
i G = Gear ratio of the individual gears = ZG 2 : ZG 1 = 34 : 45 =
0,756
iA = Transmission ratio for bevel gear assembly = ZA 2 : ZA1 =
60 : 19 = 3,158
By multiplying the gear ration, one obtains the highest gear and
the axle drive. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
itotal. = Total reduction ratio = iG x iA = 0.756 x 3.158 = 2.387
1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear

4 Code, engine allocation

⇒ “5 Filling quantity”, page 7 .
⇒ “4.1 Ibiza 2008 ►, Ibiza ST 2010 ►”, page 5
⇒ “4.2 Toledo 2013 ►”, page 5
4.1 Ibiza 2008 ►, Ibiza ST 2010 ►

When spare parts are required for repair work, the codes of the
gearbox must be observed.
Manual gearbox hous‐ 5-speed 02R
ing
Engine code LBQ JXY JDD KFK, MZL MUX MAL, MNY,
MZK, MZN
Assignment Type Ibiza 2008 ► Ibiza 2008 ► Ibiza 2008 ► Ibiza 2008 Ibiza 2008 Ibiza 2008
►, Ibiza ST ►, Ibiza ST ►, Ibiza ST
2010► 2010► 2010►
Engine 1.9 l - TDI 1.9 l - TDI 1.4l - TDI 1.6l - TDI 1.6l - TDI 1.2l - TDI
DPF 77 DPF 77 kW / DPF 59 kW CR 66 kW / CR 77 kW CR 55 kW
kW / 1.9 l - 1.9 l - TDI 1.6l - TDI
TDI DPF 66 DPF 66 kW CR 77 kW
kW
Gear ratio: Final 60 : 19 = 60 : 19 = 60 : 19 = 60 : 19 = 62 : 17 = 61 : 18 =
Z2 : Z1 group 3,158 3,158 3,158 3,158 3,647 3,388
1. th 34 : 09 = 34 : 09 = 34 : 09 = 34 : 09 = 34 : 09 = 34 : 09 =
gear 3,778 3,778 3,778 3,778 3,778 3,778
2. th 36 : 17 = 33 : 16 = 33 : 16 = 36 : 17 = 36 : 17 = 36 : 17 =
gear 2,117 2,062 2,062 2,117 2,117 2,117
3. th 33 : 26 = 34 : 26 = 30 : 24 =
33 : 26 = 34 : 25 = 33 : 26 =
gear 1,269 1,307 by SEAT S.A. 1,250 1,269 1,36 1,269
respect to the correctness of information in this document. Copyright
4. th 32 : 37 = 33 : 36 = 27 : 32 = 32 : 37 = 34 : 35 = 32 : 37 =
gear 0,864 0,916 0,843 0,864 0,971 0,864
5. th 30 : 48 = 28 : 40 = 27 : 41 = 31 : 47 = 33 : 45 = 31 : 47 =
gear 0,625 0,700 0,658 0,659 0,733 0,659
Re‐ 18:09 X 18:09 X 18:09 X 18:09 X 18:09 X 18:09 X
verse 36:20 = 36:20 = 36:20 = 36:20 = 36:20 = 36:20 =
3,600 3,600 3,600 3,600 3,600 3,600
4.2 Toledo 2013 ►

When spare parts are required for repair work, the codes of the
gearbox must be observed.
Manual gearbox housing 5-speed 02R
Engine code MZL, MZM, PPH, MZS RSY
QXR
Assignment Type Toledo 2013 ►
Engine 1.6l - TDI CR 66 kW / 1.6l - TDI CR 77 kW 1.6l - TDI CR 85 kW
77 kW
Gear ratio: Final group 60 : 19 = 3,158 62 : 17 = 3,647 60 : 19 = 3,158
Z2 : Z1
1. th gear 34 : 09 = 3,778 34 : 09 = 3,778 34 : 09 = 3,778
2. th gear 36 : 17 = 2,118 36 : 17 = 2,118 36 : 17 = 2,118
3. th gear 33 : 26 = 1,269 34 : 25 = 1,360 33 : 26 = 1,269
4. th gear 32 : 37 = 0,865 34 : 35 = 0,971 32 : 37 = 0,865
4. Code, engine allocation 5

Manual gearbox housing 5-speed 02R

Engine code MZL, MZM, PPH, MZS RSY
QXR
5. th gear 31 : 47 = 0,660 33 : 45 = 0,733 31 : 47 = 0,660
Reverse 18:09 X 36:20 = 18:09 X 36:20 = 18:09 X 36:20 =
3,600 3,600 3,600

5 Filling quantity
⇒ “4 Code, engine allocation”, page 5
⇒ “5.1 Ibiza 2008 ►, Ibiza ST 2010 ►”, page 7
⇒ “5.2 Toledo 2013 ►”, page 7
5.1 Ibiza 2008 ►, Ibiza ST 2010 ►

Engine code LBQ JXY JDD KFK, MZL MUX MAL,
MNY,
MZK, MZN
Filling quantity 2 litres
Specification Refer to ⇒ Electronic parts catalogue “ETKA” .
Clutch operation hydraulic
Clutch plate ∅ mm Refer to ⇒ Electronic parts catalogue “ETKA” .
Differential flanged shaft ∅ 108 100
mm
I
total in top gear 3.158 x 3.158 x 0.7 3.158 x 3.158 x 3.647 x 3.388 x
0.625 = = 2.210 0.658 = 0.659 = 0.733 = 0.659 =
1.973 2.077 2.081 2.673 2.232
5.2 Toledo 2013 ►

Engine code MZL, MZM, MZS, PPH, QXR, RSY
Filling quantity 2 litres
Gearbox oil Refer to ⇒ Electronic parts catalogue “ETKA” .
Clutch operation hydraulic
Clutch plate Refer to ⇒ Electronic parts catalogue “ETKA” .
Differential flanged shaft ∅ 100
mm
5. Filling quantity 7
6 General repair instructions

For proper repair of the gearbox, it is important to work with the
greatest of care and absolute cleanliness, and to use tools that
are in perfect condition. Naturally, the customary basic safety
rules must be observed during repair work.
A series of general instructions for repair work is now listed, and
these are mentioned several times throughout the course of the
Repair Manual. They apply for this particular workshop manual.
6.1 Gearbox
♦ When installing, ensure that the dowel sleeves between the
engine and gearbox are correctly located.
♦ When installing mounting brackets or waxed components,
clean the contact surfaces. The contact surfaces must be free
of wax and grease.
♦ Allocate bolts and other components using ⇒ Electronic parts
catalogue “ETKA” .
♦ After installing, check oil level ⇒ page 81 .
♦ Capacity 2.0 l.
6.2 Gaskets, seals

♦ Renew seals and gaskets.
♦ After removing gaskets and seals, always inspect contact sur‐
face of housing or shaft for burrs or other signs of damage.
♦ Lightly oil outer diameter of radial oil seals before installation.
♦ Fill space between sealing lips half full with sealing grease -
G 052 128 A1- -arrow-
♦ The open side of the seals should face the liquid to be retained.
♦ After installing, check oil level ⇒ page 81 . permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Lightly oil the O-rings before installation, to prevent them from
being pressed together during installation.
6.3 Sealant
♦ Thoroughly clean housing joint surfaces before applying seal‐
ing paste.
♦ Apply sealing paste - AMV 188 200 03- uniformly but not too
thick.
♦ No sealing paste should be allowed to enter vent holes.

6.4 Locking devices

♦ Renew retaining rings.
♦ Do not overstretch retaining rings.
♦ The retaining rings must locate properly in the grooves.
♦ Replace clamping sleeve -A-. Installation position: the groove
must face parallel to the direction in which force is transferred.
6.5 Bolts, nuts

♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Especially delicate parts, such as clutch pressure plates, must
not be distorted. Loosen and tighten bolts and nuts in stages
in diagonal sequence.
♦ The tightening torque values listed apply to unlubricated nuts,
bolts and screws.
♦ Always renew self-locking nuts and bolts.
♦ Ensure with threaded connections that contact surfaces as
well as nuts and bolts are rewaxed only after assembly, if nec‐
essary.
♦ Use thread tap to remove remains of locking fluid from all
threaded holes in which self-locking bolts are to be screwed.
Otherwise, there is a risk of the bolts breaking when next re‐
moved
♦ Check pitch of thread, to ensure correct thread chaser is used
to clean threads and to ensure the threads are not damaged.
6.6 Antifriction bearings

♦ Install new tapered roller bearings as supplied; do not lubricate
additionally with oil.
♦ Install needle bearings with lettered side unless
(thicker metal) to‐ S.A. SEAT S.A does not guarantee or accept any liability with
permitted authorised by SEAT
wards fitting tool. respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ Conical roller bearings fitted into one same shaft must be re‐
placed together. They must have the same manufacturer.
♦ Use inductive heater - VAS 6414- to heat to approx. 100°C
before installing the inner bearing race.
♦ Do not interchange outer or inner races of bearings of the
same size. The bearings are matched in pairs. The bearings
come in matched pairs.
6.7 Shims
♦ Check shim settings at various points, using a micrometer.
The various thicknesses make it possible to achieve the exact
shim thickness required.
6. General repair instructions 9

♦ Check that it is not burred or damaged.

♦ Only fit shims in perfect state.
6.8 Synchromesh rings

♦ Do not mix them up. When reusing synchro-rings, always fit to
the same selector gear.
♦ Check for wear and renew if necessary.
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
flat spots (worn grooves).
♦ Make sure that the coating of coated synchro-rings is not dam‐
aged.
♦ If an intermediate ring -B- is installed, check the outer friction
surface -arrow 2- and inner friction surface -arrow 3- of this
intermediate ring for »scoring«, »signs of wear« and »blue
discolouration (due to overheating)«.
♦ Check cone of synchromeshed gear for »scoring« and »signs
of wear«.
♦ Lubricate synchro-rings with gear oil before installing.
6.9 Gear wheels

♦ Before engaging the gear wheels, clean thoroughly and heat

to max. 100 °C using the inductive heater - VAS 6414- .
6.10 Mobile pinions

♦ After assembly, check synchromeshed gears for slight play, or
for freedom of movement.
6.11 Coupling unit

♦ Ensure that the pressure plate does not cant: loosen and tight‐
en bolts diagonally and in several gradual stages.
♦ If the clutch has burnt out, thoroughly clean the clutch housing
as well as the friction surface of flywheel with a cloth to reduce
the smell of burnt linings.

7 Safety precautions 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).
7. Safety precautions for vehicles with start/stop system 11

30 – Clutch
1 Clutch mechanism: repairs
⇒ “1.1 Clutch mechanism: assembly overview”, page 12
⇒ “1.2 Assembly overview - pedal cluster”, page 14
⇒ “1.3 Removing and installing clutch pedal switch F36 ”,
page 15
⇒ “1.4 Removing and installing mounting bracket with clutch mas‐
ter cylinder”, page 16
⇒ “1.5 Removing and installing clutch pedal with over-centre
spring, left-hand drive vehicle”, page 19
⇒ “1.6 Removing and installing clutch pedal, left-hand drive vehi‐
cle”, page 22
⇒ “1.7 Assembly overview - hydraulics (LHD)”, page 24
⇒ “1.8 Assembly overview -permitted
hydraulics (RHD)”, page 26
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
⇒ “1.9 Removing and installing clutch master cylinder”,

page 28
⇒ “1.10 Removing and installing clutch slave cylinder”,
page 29
⇒ “1.11 Bleeding clutch system”, page 30
1.1 Clutch mechanism: assembly overview
Note
♦ For vehicles fitted with a coded radio, first check the anti-theft code
♦ With the ignition OFF, disconnect the mass connection from the battery.
♦ When the battery is reconnected, coding must be carried out according to the fitted equipment; enter the
radio code, adjust the clock.
♦ Lubricate the support points and contact surfaces with polycarbamide grease ⇒ Spare parts catalogue .
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
12 Rep. gr.30 - Clutch

I - Assembly diagram - pedal

assembly ⇒ page 14
II - Assembly overview - hy‐
draulics (LHD) ⇒ page 24
II - Assembly overview - hy‐
draulics (RHD) ⇒ page 26
1. Clutch mechanism: repairs 13

1.2 Assembly overview - pedal cluster
1 - Bulkhead of the plenum

chamber
❑ With support for mount‐
ing bracket and master
cylinder
2 - Mounting bracket
❑ Removing and installing
clutch master cylinder
⇒ page 16
3 - Checking clutch pedal
switch - F36-
❑ For removal, rotate it
45º to the left and re‐
move it from its allot‐
ment
❑ Fit the clutch pedal
switch into mount and
turn 45 to right.
4 - Crash bar
5 - Hexagonal bolt
❑ 20 Nm
6 - Hexagonal nut
❑ 25 Nm
❑ Self-locking
❑ Always replace
7 - Bearing pin
❑ Always replace
8 - Over-centre spring
❑ Removing and instal‐
ling, LHD ⇒ page 19
❑ Removing and instal‐
ling, RHD ⇒ page 22
9 - Clutch pedal
❑ Removing and installing with over-centre spring, LHD ⇒ page 19
❑ Removing and installing, RHD ⇒ page 22
10 - Drift sleeve
11 - Cover cap for the pedal
12 - Mounting bracket Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing ⇒ page 26 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Driving in ⇒ page 26
13 - Clutch master cylinder
❑ Removing and installing ⇒ page 28
14 - Securing ring
❑ To remove and install pipe / hose assembly, pull out the ring as far as it will go
❑ Pulled out to side on some slave cylinders
15 - Seal
❑ Always replace

16 - Flexible hose
17 - Clutch position sender - G476-
❑ For vehicles with start stop system
❑ Allocate components using ⇒ Electronic parts catalogue (ETKA)
❑ Removing ⇒ page 18
❑ Installing ⇒ page 19
❑ Can be checked in “Guided fault finding”, using vehicle diagnostic, testing and information system - VAS
505X- .
1.3 Removing and installing clutch pedal

switch - F36 -
⇒ “1.3.1 Detaching”, page 15
⇒ “1.3.2 Attaching”, page 15
Note
So that it is correctly fitted in the clutch pedal bracket, the clutch
pedal switch - F36- should only be fitted once.
1.3.1 Detaching
– Remove the driver side foot well cover ⇒ Bodywork, interior
fitting work; Rep. gr. 68 .
– Pull connector off clutch pedal switch - F36 - .
– Rotate the clutch pedal switch - F36 - -1- 45° to the left and
pull it out of the position.
Note
The clutch pedal remains in rest position, that is, not pressed.
1.3.2 Attaching
• The pedal must be in resting position.
– Lubricate the end of the rod with molybdenum paste
N05214200⇒ Spare parts catalogue .
– Insert the clutch pedal switch - F36- through the installation
hole, pressing it against the clutch pedal and securing it by
rotating 45° to the right.
– Plug in the connector of the clutch pedal switch - F36 - .
– Install the driver side foot well cover ⇒ Bodywork, interior fit‐
ting work; Rep. gr. 68 .

1.4 Removing and installing mounting

bracket with clutch master cylinder
Special tools and workshop equipment required
♦ Hose clamps to 25 mm - 3094-
♦ Torque wrenches - V.A.G 1331-
♦ Sealing tool - T10249-
1.4.1 Detaching
Left-hand drive vehicle
– Then remove complete air filter housing if it is preventing ac‐
cess to master cylinder ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24 .
– Remove engine control unit from bulkhead if it is preventing
access to master cylinder ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24

Right-hand drive vehicles

In some vehicles, master cylinder is located behind a line for air
conditioning system -arrow-.
An insulation mat is installed in conjunction with some engines.
Appearance may be different from that illustrated.
– Remove the insulating element -arrows-.

Continuation for all vehicles
Note
♦ During the following work, ensure that no brake fluid lands on

longitudinal member or gearbox. If this does happen, clean the
affected area thoroughly.
♦ Place a lint-free cloth under the master cylinder.
– Clamp off supply hose to master cylinder using hose clamp -

3094- .
– Disconnect supply hose -1- from master cylinder.
– In addition, for disconnecting, you can close it with the sealing
tool - T10249/1- (⇒ figure above).
– Disengage the safety fastener -2- with a screwdriver or tipped
object, and uncouple the pipe and hose assembly -3- from the
clutch master cylinder.
Note respect to the correctness of information in this document. Copyright by SEAT S.A.
With several master cylinders, the securing clip -2- can also be
pulled out to the side.

Vehicles with start/stop system:

– Separate clutch position sender - G476- from master cylinder
-arrow A- and -arrow B-.
– Remove clutch position sender from master cylinder with con‐
nector connected.
Note
When working in footwell, cover carpet with cloths to protect it

against brake fluid spillage.
– Remove the driver side foot well cover ⇒ Bodywork, interior

– If fitted, remove crash bar -arrow-.

– Rotate the clutch pedal switch - F36- -1- 45° to the left and pull
it out of the position.
– Unscrew the hexagonal nuts ⇒ Item 6 (page 14) and remove
the bearing block from the front panel along with the clutch
master cylinder. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1.4.2 Attaching
– Mount the bearing block and master cylinder to the front wall
and tighten the new bolts to the torque of 25 Nm.
– Fit the clutch pedal switch - F36- in its allotment and turn 45°
to the right.
– Fit the crash strap of the clutch pedal and tighten the fastening
bolt to a torque of 20 Nm.

– Install the driver side foot well cover ⇒ Bodywork, interior fit‐
ting work; Rep. gr. 68 .
Vehicles with start/stop system:
– Insert the clutch position sender - G476- up to the end of the
clutch master cylinder when the connector is closed.
• Clutch position sender must clip in -arrow A-.
– To check, pull on clutch position sender -arrow B-.
– After removing hose clamp - 3094- , supply hose -1- must be
returned to its original position and shape.
– Press in pipe and hose assembly or plastic line -2- into the
slave clutch cylinder connection until safety fastener -2- is au‐
dibly secured.
– Test line by tugging
respecton it. correctness of information in this document. Copyright by SEAT S.A.
to the
– Hydraulic clutch system: bleeding of air ⇒ page 30 .

Left-hand drive vehicle
– If engine control unit was removed, fit it onto bulkhead ⇒ Rep.
gr. 23 or ⇒ Rep. gr. 24
– If removed, mount the complete air filter housing ⇒ Rep. gr.
23 or ⇒ Rep. gr. 24 .
1.5 Removing and installing clutch pedal

with over-centre spring, left-hand drive
vehicle
⇒ “1.5.2 Installing”, page 20
Note
♦ Install clutch pedal with a new bearing shaft.

♦ When the over-centre spring should only be removed, the
clutch pedal does not have to be removed from the master
cylinder.

♦ Pliers - T10005-
♦ Allen key, 8 mm AF, commercially available

1.5.1 Detaching
– Remove the crash strap from the clutch pedal by removing the
fastening bolt -arrow-.
– Rotate the clutch pedal switch - F36- -1- 45° to the left and pull
it out of the position.
– Release clutch master cylinder operating rod from clutch pedal

as described in the following:
– Slightly pull the clutch pedal towards the inside of the vehicle.
– Press both sides of retaining clip inwards using pliers -
T10005- -arrows-.
– Remove bearing shaft for clutch pedal.

– To do this, turn bearing shaft for clutch pedal to left
-direction of arrow-.
-1- = Allen key, 8 mm AF.
Locking devices -A- are irreparably damaged.
Pins -B- are then horizontal.
– Move clutch pedal so you can pull out bearing shaft.
– Take out over-centre spring.
– Remove clutch pedal.
1.5.2 Installing
• Install clutch pedal with a new bearing shaft.

– Make sure that support -2- is located on operating rod -1- of

clutch master cylinder.
– Press retainer into notch in clutch pedal -3- until it can be heard
to engage.
– Insert the over-centre spring on the side from underneath next

to the plunger of the master cylinder and next to the clutch
pedal in the bracket -A- in Protected
the bearing bock.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Receptacle -arrow- for tip of clutch pedal
respect to must be
the correctness vertical.
of information in this document. Copyright by SEAT S.A.
– Now position over-centre spring on mounting lug of clutch

pedal -arrow-.
– Press on clutch pedal slightly and push new bearing shaft

through.
– Place pins -A- horizontally.
– Turn bearing shaft to right -direction of arrow-.
• Locking devices -B- must audibly engage.
Pins -A- are then vertical.
– Fit the clutch pedal switch - F36- in its allotment and turn 45°
to the right.
– Fit the crash strap of the clutch pedal and tighten the fastening
bolt to a torque of 20 Nm.

1.6 Removing and installing clutch pedal,

left-hand drive vehicle
Note
♦ Install clutch pedal with a new bearing shaft.

♦ If you only wish to remove over-centre spring, then clutch ped‐
al does not need to be removed from mounting bracket.

♦ Pliers - T10005-
♦ Allen key, 8 mm AF, commercially available

♦ In addition
Protectedfor clutch Copying
by copyright. pedal for
with extension
private spring:
or commercial purposes,hook
in part -or3438-
in whole, is not
1.6.1 Detaching
– Remove mounting bracket with master cylinder ⇒ page 16 .
– Set clutch pedal to rest position.

– Release clutch master cylinder operating rod from clutch pedal

as described in the following:
– Press sides of retainer inwards -arrows- using pliers - T10005-
and pull gently on clutch pedal.
Clutch pedal with extension spring
– Unhook extension spring. (Shown here with mounting bracket
installed.)
Right-hand part of figure -arrows- only applies to installation.

Clutch pedal with over-centre spring
– Press over-centre spring in -direction of arrow- and remove

downwards.
– Remove bearing shaft for clutch pedal.

– To do this, turn bearing shaft for clutch pedal to left
Locking devices -A- are irreparably damaged.
Pins -B- are then horizontal.
– Remove bearing shaft and take off clutch pedal.

1.6.2 Installing
• Insert clutch pedal with new bearing shaft.
– Place pins -A- horizontally.
– Turn bearing shaft to right -direction of arrow-.
• Locking devices -B- must audibly engage.
Pins -A- are then vertical.
– Set clutch pedal to rest position.
Clutch pedal with over-centre spring
– First attach the over-centre spring on the mount at the rear.

– Now press over-centre spring onto mounting lug of clutch ped‐
al -arrow-.
Clutch pedal with extension spring
– Hook in extension spring. (Shown here with mounting bracket

installed.)
– Insert vibration damper with recess -arrows- from second
spring winding onwards -arrows-.
– Make sure that support -1- is located on operating rod -2-.

to engage.
– Install mounting bracket ⇒ page 16 .
1.7 Assembly overview - hydraulics (LHD)

1 - Brake fluid reservoir

2 - Supply hose
⇒ page 28
4 - Clip
❑ To remove and install
pipe/hose assembly,
pull out clip as far as it
will go
❑ Renew only with master
cylinder removed
❑ Insertion ⇒ page 26
6 - Clutch pedal
7 - Self-locking hexagon nut,
25 Nm
❑ Always replace
8 - Seals / O-rings
❑ Pull onto line connection
❑ Lubricate with brake flu‐
id before installing
❑ Seals/O-rings are adap‐
ted to configuration of
line connection
⇒ page 26
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
9 - Pipe and hose assembly
❑ Determine according to
⇒ Electronic parts catalogue (ETKA) .
❑ For removal, the ABS control unit must be removed along with the hydraulic unit ⇒ Brake system; Rep.
gr. 45
10 - Rear bracket
❑ Attached to body
11 - Rear bracket
❑ Depending on version
❑ Secured to slave cylinder of gearbox.
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
12 - Flange bolt, 20 Nm
13 - Bleeder valve
❑ Bleed the clutch
Protected by copyright. Copying⇒
system forpage 30commercial purposes, in part or in whole, is not
private or
14 - Closing cap
15 - Clip
❑ To remove and install pipe/hose assembly, pull out clip as far as it will go
16 - Gearbox
17 - Clutch slave cylinder
❑ removing and fitting ⇒ page 29

Levering retaining clip -A- off in direction of arrow
Carefully push support -A- onto master cylinder operating rod
Seals and O-rings for pipe and hose lines

Item Material of line connection
1 Line connection with circumferential groove
-arrow 1-
2 Line connection with shoulder -arrow 2-
3 Line connection with shoulder -arrow 2- and cir‐
cumferential groove -arrow 3-
• For line connection having circumferential groove -arrow 1-
and -arrow 3-, a seal or O-ring must be set there.
Supply hose -1- of plastic

• The seals -2- must be located in supply hose.
1.8 Assembly overview - hydraulics (RHD)


1 - Brake fluid reservoir

2 - Spring clip
❑ Not fitted in all vehicles
3 - Supply hose
⇒ page 28
❑ Renew only with master
cylinder removed
6 - Clutch pedal
7 - Clamp
❑ Pull clip out to stop to re‐
move pipe/hose line
8 - Self-locking hexagon nut,
25 Nm
❑ Always replace
9 - Brake lines
10 - Rear bracket
11 - Rear bracket
❑ For brake lines and
pipe/hose line
12 - Rear bracket
❑ For brake lines and
pipe/hose line
13 - Seals / O-rings
❑ Pull onto line connection
❑ Lubricate with brake fluid before installing
❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 26
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
14 - Pipe and hose assembly
❑ Determine according to ⇒ Electronic parts catalogue (ETKA) .
15 - Rear bracket
16 - Rear bracket
❑ Depending on version respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Secured to slave cylinder of gearbox.


17 - Hexagon bolt, 20 Nm
18 - Closing cap
19 - Bleeder valve
❑ Bleed the clutch system ⇒ page 30 .
20 - Flange bolt, 20 Nm
22 - Clamp
❑ To remove and install pipe/hose assembly, pull out clip as far as it will go
23 - Gearbox
1.9 Removing and installing clutch master

cylinder
♦ Pliers - T10005-
1.9.1 Detaching
Remove the mounting bracket along with the master clutch cyl‐
inder ⇒ page 16 .
– Release clutch pedal from master cylinder with pliers -
T10005- .
– Remove the clutch master cylinder from the bearing block.

1.9.2 Installing
– Remove the clutch master cylinder from the mounting block.
– Make sure that support -1- is located on operating rod -2-.
to engage.
Install mounting bracket with master cylinder ⇒ page 16 .
1.10 Removing and installing clutch slave

cylinder
1.10.1 Detaching
– Remove complete air filter housing if it is preventing access to
master cylinder ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24 .
– Fit a lint-free cloth under the clutch slave cylinder.
– Pull clip for pipe/hose line out of slave cylinder to stop.
– Pull pipe/hose line out of slave cylinder and seal opening.
– Remove slave cylinder -arrows-.
Caution
Do not operate clutch pedal after disconnecting pipe/hose as‐

sembly.
1.10.2 Attaching
Installation is carried out in the reverse order. When installing,
note the following:

– Install slave cylinder and tighten bolts -arrows- to specified

torque ⇒ Item 20 (page 28) .
– Insert pipe/hose line into slave cylinder to stop.
– Push retaining clip into pipe/hose line to stop.
– Test pipe/hose line by tugging on it.
– Bleed the clutch circuit after installing slave cylinder
⇒ page 30 .
23 or ⇒ Rep. gr. 24 .
1.11 Bleeding clutch system

♦ Brake filling and bleeding unit - VAS 5234-
Note
Prefilling the system is not necessary.
Brake fluid specification ⇒ Brake system; Rep. gr. 47 .

– The filter must be removed if there is no access to the slave
cylinder ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24 .
– Connect the brake filling and bleeding device - VAS 5234- .
To bleed system, use 670 mm bleeder hose - V.A.G 1238/B3- if
necessary.
– Connect bleeder hose to collector bottle of brake bleeding
equipment.

– Connect bleeder hose to bleeder -arrow-.

– Pressurise system to 2 bar.
– Open bleeder valve.
– Allow approx. 100 cm3 of brake fluid to run out.
– Close the bleed screw.
– Step on the pedal and release it quickly 10 to 15 times.
– Open bleeder valve.
– Allow another 50 cm3 of brake fluid to flow out.
– Close the bleed screw.
– Depress clutch pedal several times after completion of bleed‐
ing process.

2 Clutch release assembly: repairs
1 - Gearbox
2 - Spherical head pin
❑ 25 Nm
❑ Remove old grease
from contact surface of
clutch release lever
❑ Grease with lubrication
grease ⇒ Parts Cata‐
logue
3 - Join ring for the input shaft
❑ Replace
⇒ Item 13 (page 111)
4 - Guide bushing
❑ Protected
With by vulcanised O-ring
copyright. Copying for private or commercial purposes, in part or in whole, is not
❑permitted
Replace the guide bush
and o-ring together if the
latter is damaged
❑ Lubricate the guide
bush with grease, ac‐
cording to ⇒ Spare
parts catalogue in the
clutch release collar
area
❑ Remove the clutch re‐
lease lever first
⇒ page 33
5 - Retaining spring
❑ Secure to clutch release
lever
6 - Cylindrical bolt
❑ 20 Nm
❑ 3 off
7 - Clutch release lever:
❑ Remove existing grease
8 - Release bearing
❑ Do not wash the collar Only clean it with a cloth
❑ Replace if it is making noise
❑ Grease the contact points with the clutch release lever using lubricating grease ⇒ Spare parts catalogue
9 - Plug
❑ 20 Nm
11 - Plunger
❑ Lubricate the end of the tappet with lubricating grease, according to ⇒ Spare parts catalogue .
12 - Assembly bolt
❑ Secure the clutch release lever when fitting the complete gearbox
❑ It must be unscrewed after installing the gearbox

Note
If there is no assembly bolt, bolt M8

x 25 can be used
Removing and installing clutch release lever with release bearing

and guide sleeve
Detaching
– Unhook the spring -1- upwards.
– Remove the clutch release lever -arrow 2- from the spherical
pivot.
Installing
– Fit the spring -arrow 1- on clutch release lever first.
– Press on the clutch release lever -arrow 2- onto the spherical
pivot.
Removing and fitting the clutch release socket

– Press on the securing tabs -arrows- and take the clutch re‐
lease socket -A- from the clutch release lever.
– To assemble, press the clutch release bearing -A- into the
clutch release lever until the tabs -arrows- are in position.
2. Clutch release assembly: repairs 33

3 Clutch: repairing
Special tools and workshop

equipment required
♦ retention tool - 3067-
♦ Centring mandrel. - 3190 A-
♦ Torque wrench - V.A.G
1331-
♦ Grease for clutch plate
splines - G 000 100-
Note
♦ Always replace clutch disks and pressure plates with damaged or loose rivet connection.
♦ Select correct clutch plate and pressure plate by checking the ⇒ Electronic parts catalogue (ETKA) and the
engine code.
♦ Check if the centring sleeves are installed in the engine for the purpose of centring the engine with the
gearbox and insert these if they are not installed.
♦ If the dowel sleeves are not fitted, this will lead to gear-change problems, clutch malfunction and in some
cases gearbox noise (gears will make rattling noises).

1 - Flywheel
⇒ Rep. gr. 13
❑ Make sure that the cen‐
tring pins have a tight fit.
❑ Keep contact surface for
clutch lining free of
grooves, oil and grease.
2 - Clutch plate
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
❑ Installation position on
the dual-mass flywheel
⇒ page 36
❑ Installation position for
single flywheel: the
mount of the spring
must be positioned in
the direction of the pres‐
sure plate
❑ Centralising
⇒ page 36
❑ Lightly grease splines
Note
Clean input shaft splines and (in the

case of used clutch plates) the hub
splines. Remove corrosion and ap‐
ply only a very thin coating of grease
- G 000 100- to the splines of the in‐
put shaft. Then move the clutch
plate on the input shaft from side to
side, until the hub moves smoothly
on the shaft. Excess grease must be
removed.
3 - Pressure plate
❑ Checking ends of diaphragm spring ⇒ page 36
❑ Check the elastic and riveted joints ⇒ page 36
Note
The pressure plates are greased

and protected against corrosion.
Clean contact surface only. Other‐
wise, the service life of the clutch willProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
be considerably reduced. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
4 - Bolts M 6, 13 Nm, Bolts M 7, 20 Nm
❑ Corresponding to ⇒ Electronic catalogue of spare parts“ETKA”
❑ Loosen or tighten diagonally and in steps
3. Clutch: repairing 35
Central clutch disk and remove and install the pressure plate
– Loosen or tighten bolts diagonally in stages.
– Re-position the counterhold - 3067- when removing.
Note
Pressure plate contact surface and clutch plate lining must make
full contact with flywheel. Tighten securing bolts diagonally and
evenly to prevent damage to pressure plate centring hole and fly‐
wheel centring pins.
Installation position of clutch plate in conjunction with dual-mass

flywheel
• The lettering “Getriebeseite” should face towards the gearbox.
Check ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring is per‐
mitted.
Check the elastic and riveted joints

– Check if there are cracks on the elastic connections between
pressure plate and cover and make sure rivet fastenings are
seated tightly. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Always replace clutch disks and respect
pressure plates with
to the correctness dam‐ in this document. Copyright by SEAT S.A.
of information
aged or loose spring connection -arrows-.

34 – Controls, housing
1 Gear mechanism: repairing
⇒ “1.1 Shifting: installation position”, page 37
⇒ “1.2 Gear stick handle with cover - Installation overview”, page
39
⇒ “1.3 Removing and installing the gear stick handle”,
page 39
⇒ “1.4 Gear selection mechanism:installation overview”,
page 40
⇒ “1.5 Gear selection mechanism cables: removing and fitting;
general overview”, page 43
⇒ “1.6 Gearbox mechanism: removing and fitting”, page 47
⇒ “1.7 Gear drive mechanism: adjustment”, page 49
1.1 Shifting: installation position

-Arrow A-: movement for gear engagement
-Arrow B-: movement for gear track selection
A - Gear selector cable

B - Gate selector cable
C - Heat shield
❑ Remove before remov‐
ing gear selector mech‐
anism
1 - Gear lever
2 - Return lever
1. Gear mechanism: repairing 37

Gear selection mechanism: removing and fitting ⇒ page 47

Gear drive mechanism: adjustment ⇒ page 49
Note
♦ With the ignition OFF, disconnect the mass connection from the battery.
♦ For vehicles fitted with a coded radio, first check the anti-theft code
♦ When the battery is reconnected, coding must be carried out according to the fitted equipment; enter the
radio code, adjust the clock.
♦ Do not bend the control cables
I - Gear stick handle with cover:

Installation overview
⇒ page 39
II - Shifting: Assembly survey
⇒ page 40
III - Assembly overview - se‐
lector level cable ⇒ page 43
38 Rep. gr.34 - Controls, housing

1.2 Gear stick handle with cover - Installation overview
1 - Gear lever knob

with bellows
⇒ page 39
2 - Grommet
3 - Clamp
❑ To secure knob onto
gear lever
4 - Lever bellows
❑ Remove and fit along
with the gear lever knob
❑ removing and installing
⇒ page 39
5 - Securing frame
❑ Removing and fitting : ⇒
Bodywork, interior fitting
work; Rep. gr. 68
1.3 Removing and installing the gear stick

handlerespect to the correctness of information in this document. Copyright by SEAT S.A.

♦ Removal wedge - 3409-

♦ Hose clip pliers - V.A.G 1275 A-
Detaching
– Lever off boot using removal wedge - 3409- on alternate sides
-arrow- and pull off upwards.
– Pull gaiter upwards, inside out over gear knob.
– Open clamp -arrow- and pull off gear knob together with gaiter.
Installation
– Turn dust cover over.
The gear knob must be pressed to stop.
– Install gear knob and gaiter and squeeze new clamp -arrow-
together.
1.4 Gear selection mechanism:installation

overview

♦ Assembly tool - T10236-
Note
♦ Lubricate bearing positions and sliding surfaces.

1 - Retainer washer
⇒ page 42
2 - Compression spring
⇒ page 42
3 - Gasket
❑ Between protection
housing and floor
❑ Self-adhesive
❑ Bond to selector hous‐
ing
4 - Gear lever
5 - Damper
❑ removing and fitting
⇒ page 42
6 - Lever protection box
❑
7 - Damping washer
❑ MustProtected
be located in Copying for private or commercial purposes, in part or in whole, is not
by copyright.
groove -arrows-
permitted in gear
lever respect to the correctness of information in this document. Copyright by SEAT S.A.
8 - Seal
❑ Always replace
9 - Lower plate
❑ To disassemble, open
the tabs
❑ Always replace
10 - Drift sleeve
11 - Selection control cable
❑ Pry off using release tool - T10236-
❑ Press onto gate selector lever inside selector mechanism

❑ Installation position ⇒ page 37

12 - Gear selector cable
❑ Pry off using release tool - T10236-
❑ Press onto gear lever guide inside selector mechanism
13 - Hexagon nut M8, 25 Nm, hexagon nut M 6, 8 Nm
❑ 4 off
Removing and installing damping -arrow-

– Press extension -A- of spring to the left until it is next to damp‐
ing -arrow-.
– Move gear lever to left and pull off damping.
• After installation, damping must contact extensions -A- and
-B-.
Removing and installing securing clip and spring

– For removing and installing the securing clip -arrow A-, the
pressure spring must be pressed to the stop in
-the direction of arrow C- and the securing washer is pulled
out.
Note
♦ Disregarding of pos. B of the throttle cap cam is pressed in.

♦ The groove in the gear lever where the securing ring is seated
must be in sight.
♦ Loosen the spring carefully.

1.5 Gear selection mechanism cables: removing and fitting; general overview
Note
Lubricate the support points and contact surfaces with polycarbamide grease ⇒ Spare parts catalogue .
1 - Gear engagement cable

❑ Fit into the gear lever
guide
❑ Installation position
⇒ page 37
2 - Cable for gear track selec‐
tion
❑ Connects to the selector
bracket
⇒ page 37
3 - Retainer washer
4 - Retainer washer
❑ Do not damage the ca‐
bles when disassem‐
bling
5 - Gear stick protective cover
6 - Counter support
7 - Sleeve
❑ Counter support bracket
on the gearbox
8 - Spacer
9 - Hexagonal bolt
❑ 25 Nm
❑ For counter support
10 - Hexagonal nut
❑ 25 Nm
11 - Gear lever
❑ with balancing weight
❑ Insert so that the discon‐
tinuous cogs coincide with the selector shaft.
❑ Once fitted, adjust the gear operation mechanism ⇒ page 49
12 - Cable end-piece
❑ To secure the gear engagement cable to the selection rod
❑ Always replace when the selection rod is removed
13 - Retainer washer
❑ Always replaceProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
14 - Runner
15 - Relay lever

❑ removing and installing ⇒ page 45

❑ Once fitted, adjust the gear operation mechanism ⇒ page 49
16 - Cable end-piece
❑ To secure the gear track selection cable to the relay lever
❑ Always replace when the relay lever is removed
Fit the idler rod

– When installing gearbox selector lever, make sure that the gap
in the splines -arrow A- aligns with the wider spline -arrow B-
on the selector shaft.
Installation position of gearbox selector lever and relay lever

• Relay lever engages in guide rail of gearbox selector lever via
shoe -arrow-.

Relay lever: removing and installing
WARNING
♦ Before removing the idler rod, leave the gearbox mecha‐

nism in neutral, so that the rod is free.
♦ To remove it, separate the selector cable fastener so that
the cable is not damaged.
Detach the fastening element from the connection cable

– Pull the safety mechanism forwards, as far as possible to‐
wards -arrow 1-, then block it by turning it to the right, in the
direction of -arrow 2-.
– Then press relay lever forwards (in direction of -arrow 3-).
Relay lever with catch -arrow 1- (⇒ previous figure)
– Press catch -arrow 1- (⇒ previous figure) down to stop and
remove relay lever together with cable end-piece. In the proc‐
ess, swing it in direction of operation.
Relay lever with clip -arrow 1-

– Remove the clip -arrow 1- and remove the relay lever together
with the fixing elements of the cable.
Cable end-piece must be located behind catch -arrow 2-.

• When installing, grease following areas particularly carefully.

• Shaft -A- of relay lever -arrows-.
• Guide rail -B- of gearbox selector lever in which relay lever
engages.
• The relay lever and gearbox selector lever may look different
from the original part.
• Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
• The cable end-piece can be removed only with the relay lever
removed ⇒ page 46 .
Note
♦ When installing, lubricate bearing positions and sliding surfa‐

ces.
– Press cable end-piece onto relay lever ⇒ page 47 .

– Insert relay lever with cable end-piece as far as stop.
• Fastener -arrow 1- secures relay lever (⇒ previous figure).
• Ensure proper engagement.
• Cable end-piece must be located behind catch -arrow 2- (⇒
previous figure).
Levering cable end-piece for gate selector cable off plastic relay
lever
• Relay lever is removed.
– Insert a flat-blade screwdriver -A- between bush -B- and relay
lever.

Pressing on cable end-piece

• Relay lever is removed.
• Cable end-piece may be pressed only onto bush -arrow-.
• Cable end-piece must move freely on relay lever.
• It must be located behind catch -arrow 2- ⇒ page 45 .
1.6 Gearbox mechanism: removing and fit‐

ting Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “1.6.1 Detaching”, page 47 respect to the correctness of information in this document. Copyright by SEAT S.A.
⇒ “1.6.2 Installation”, page 49

⇒ “1.6.3 Specified torques”, page 49
1.6.1 Detaching
♦ Torque wrench - V.A.G 1331-

♦ Hose clip pliers - V.A.G 1275 A-
– First the vehicle should be checked if a coded radio is installed.

If necessary obtain radio anti-theft code first.
– The air filter must be removed if it is situated behind the bat‐
tery. ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24 .
Metal idler rod
– Detach securing clip -4- for gate selector cable from relay lever
-2-.
– Pull gate selector cable from pin.
– Pull securing clip off relay lever -2- and remove relay lever.
– Remove the securing clip -1- which attaches the gear selector
cable from the gearbox selector lever-3-.
– Pull gear selector cable off pin.
– Remove gearbox selector lever -1- by removing nut.
Plastic relay lever

– Release end-piece from gate selector cable ⇒ page 45 .
– Pull clip -arrow 1- off and remove relay lever together with ca‐
ble end-piece.
– Detach securing clip -arrow 2- for gear selector cable from
gearbox selector lever -A-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Pull gear selector cable off pin. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Remove gearbox selector lever -A- by removing nut

-arrow 3-.
Continue for all gearbox operation mechanisms

– Remove cable support bracket from gearbox -arrows-; if nec‐
essary unclip hose -A- on cable support bracket first.
– Remove the dust guard from the centre console frame using
the removal wedge - 3409- .

– Then destroy the clip -arrow- and pull off gear knob together
with boot.
– If noise insulation is present, remove it.
– Remove the centre console with fixing bracket ⇒ Bodywork,
interior fitting work; Rep. gr. 68 .
– Screw the fixing nuts of the selector housing -arrows- from the
bodywork.
– If insulation tray is installed below engine and gearbox, re‐
move it.
– Remove tunnel cross member and separate exhaust system
⇒ Repair group 26; Removing and installing parts of exhaust
system.
– Remove underbody panels ⇒ General body repairs, exterior;
Rep. gr. 50 .
– Swing selector housing down and remove with selector ca‐
bles.
1.6.2 Installation
Installation is carried out in the reverse order. When installing,

note the following:
– Fit relay lever and cable end-piece together ⇒ page 45 .
– Insert the selector cable in the fastening element.
– Install centre console ⇒ Bodywork, interior fitting work; Rep.
gr. 68 .
– Renew clamp -arrow-.
– Install underbody panels ⇒ General body repairs, exterior;
Rep. gr. 50 .
– Remove tunnel cross member and front section of the exhaust
pipe ⇒ Repair group 26; Removing and installing parts of ex‐
haust system .
Adjust selector mechanism ⇒ page 49 .
– Install complete air filter housing ⇒ Rep. gr. 23 or ⇒ Rep. gr.
24
1.6.3 Specified torques

Selector housing to body ⇒ Item 13 (page 42)
Selector cable support bracket to gearbox ⇒ Item 9 (page 43)
1.7 Gear drive mechanism: adjustment

⇒ “1.7.1 functioning”, page 52

♦ Roll pin - T10027 A-
Note
♦ For setting the gearbox correctly, the following requirements

must be met in all cases:
♦ The elements of the gearbox and the clutch mechanism must
be in perfect condition.
♦ Gearbox operation is smooth without stiffness.
♦ Gearbox, clutch and clutch mechanism must also be in proper
condition.
• The gearbox must be in a neutral position.

– Remove the complete air filter housing if angled rod -A- and
securing mechanism for gear selector cable and gate selector
cable are not accessible ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24 .

– Pull locking mechanisms on gate selector cable and gear se‐

lector cable end-pieces forward to stop -direction of arrow 1-
and then turn to left to lock -direction of arrow 2-.
Secure the selector shaft lever as follows:

– Press selector shaft down (direction of -arrow 1-).
– When pressing in the selector shaft, the bracket -A- must be
turned in the direction of -arrow 2-.
– Remove the dust guard from the centre console frame using
the removal wedge - 3409- .
– If noise insulation is present, remove it.
Now lock the gear lever as follows:
– Place the gearshift lever in neutral position.

– Guide locking pin - T10027 A- through hole -A- into hole -B-.
– Now turn locking mechanisms on gear selector cable and gate

selector cable end-pieces clockwise to stop
The spring returns the securing mechanism back to the initial po‐
sition.

– Now turn the angle -A- in the direction of the -arrow- until it has
reached the correct position.
Note
The angled rod -A- must be pressed out of selector housing to

stop and point to rear.
– Pull locking pin out of holes -A- and -B-.

– If noise insulation was present, install it.
– Press gaiter into console.
– Ensure that the selector shaft can move freely.
23 or ⇒ Rep. gr. 24 .
1.7.1 functioning
• With gearbox in neutral, gear lever must rest in gate for 3rd
and 4th gear.
– Engage clutch.
– Select all gears several times. Pay particular attention to op‐
eration of reverse gear lock.
– If the difficulty in engaging a gearCopying
Protected by copyright. persists afteror repeated
for private at‐ in part or in whole, is not
commercial purposes,
tempts, repeat adjustment procedure of selector mechanism
⇒ page 49 .

2 Gearbox : removing and fitting

⇒ “2.1 Removing and installing the gearbox, Ibiza 2008 ►, Ibiza
ST 2010 ►”, page 53
⇒ “2.2 Removing and installing gearbox: Toledo 2013 ►”,
page 66
2.1 Removing and installing the gearbox,

Ibiza 2008 ►, Ibiza ST 2010 ►
⇒ “2.1.3 Tightening torque”, page 65

equipment required
♦ Rear bracket - 10 222A-
♦ Adapter - 10 222A/1-
♦ Adapter - 10 222A/3-
♦ Adapter - 10 222A/10-
2. Gearbox : removing and fitting 53

♦ Adjustment plate - T30020-

♦ Engine/gearbox jack -
V.A.G 1383 A-
♦ Torque wrenches -
V.A.G 1331-
V.A.G 1332-
♦ Gearbox support assembly
- 3282-
♦ Support elements for gear‐
box (determine when set‐
ting adjustment plate on
gearbox support )
♦ Studs - 3282/29-
♦ Gearbox lifting tackle -
3336- for transporting gear‐
box
♦ Allocate grease using ⇒
Electronic parts catalogue
(ETKA) .
2.1.1 Detaching
– Disconnect the negative battery cable.
Note
Observe the measures to be adopted when disconnecting the

battery ⇒ Rep. gr. 27 .
Note
For vehicles fitted with a coded radio, first check the anti-theft
code
– Remove air cleaner housing ⇒ Rep. gr. 23 .

– Remove battery and battery retainer: ⇒ Electrical system;
Rep. gr. 27 .

– Remove nuts-2- and bolt -1- and extract the battery support.
– Remove safety washer -1- that secures the connector cable

to the selector rod.
– Remove the connector cable from the pivot.
– Remove relay lever ⇒ page 45
– Loosen the nut on the selector rod -arrow 2-and remove it from
the selector shaft.
– Dismantle the selection rod -A-.
– Detach bracket on shift control cable and selector control ca‐
ble on transmission housing. Unscrew the bolts -1- and move
the bracket to one side.
– Remove the line -3- from the support -4-.
– Remove the bracket -4- for the pipes from the gearbox.
– Remove the slave cylinder from the gearbox housing by un‐
screwing the screw -5- and move it to the side.
Note
Do not depress clutch pedal.
– Extract the upper securing bolt from the plastic tube of the in‐
tercooler-2- and loosen the metallic flange of its upper sleeve.
– Remove the securing bolt from the earth wire-1- and put it
aside.

– Disconnect the connector -arrow 1- from the starter motor and

the connector -arrow 2- from the reverse light switch.
– Lever off the protection cover and unscrew the cable
-arrow 3- from the starter motor.
– Remove the upper attachment bolts between the engine/gear‐
box.
– Extract the upper starter securing bolt.
– Raise the vehicle and remove the left front wheel.
– Remove the front left wheel housing: ⇒ Bodywork, exterior
– Remove the soundproofing tray ⇒ General body repairs, ex‐
terior; Rep. gr. 50 .
– Unscrew the lower fastening nut of the intercooler hose -A-,

detach the pipe -B- and the hose -C- from the intercooler. Re‐
move their metal clamps.
Vehicles with start / stop system
– Unplug the connector -arrow- from the gearbox neutral posi‐

tion sender - G701- .
– Unscrew the bracket -arrow- from the starter motor and put it
to one side along with the cables.
– Removing the starter motor: ⇒ Electrical system; Rep. gr. 27 .

– Remove the pendulum support -arrows 1 and 2-.
– Remove the thermal plate for the inner right hand side con‐
stant speed joint.
– Release and secure the driveshaft's ⇒ Running gear - front-
wheel drive; Rep. gr. 40 .
– Unscrew bolt -1- with gearbox installed.

– Remove protection plate -2- upwards.
– Remove the subframe ⇒ front wheel suspension; Rep. gr.
40 .
– Fit the bracket - 10 222A- with the necessary adapters and

attach as shown in the figure, and catch the motor in its in‐
stallation position.
Note
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 socket.

– Lower the engine assembly/gearbox using the spindle of the
support stand - 10 222A- .
– Remove transmission console -A-. To do this, remove the se‐

curing bolts -arrows-.
– Move the engine assembly forwards and insert a wooden
wedge between the subframe and the engine.
Assemble engine and gearbox support , gearbox support - 3282- ,
adjustment plate
unless -authorised
T30020- for S.A.
by SEAT “02R”
SEATgearbox
S.A does notand mounting
guarantee ele‐
permitted or accept any liability with
ments as follows:
– Place adjustment plate - T30020- on gearbox support - 3282-

(adjustment plate only fits in one position).
– Align arms of gearbox support according to holes in adjust‐
ment plate.
– Screw in support elements -A- and -C- as shown on adjust‐

ment plate.
– Screw in the bolts - 3282/29- as displayed on the adjustment
plate.
– Position engine and gearbox jack under vehicle. Arrow -B- on

adjustment plate points in direction of vehicle travel.
– Align adjustment plate parallel to gearbox and lock safety sup‐
port on gearbox.
– Remove lower engine/gearbox connecting bolts.

– Push the gearbox off the dowel sleeves and swing carefully
towards the subframe.
• Differential must face upwards.
– Guide gearbox with differential over sub frame -A- and swing
out.
– If necessary, turn gearbox further upwards near differential
using spindles of gearbox support - 3282- .
– Swivel gearbox further out and carefully lower.

– Turn gearbox down in area of 5th gear (sheet metal cover)
– Release the gear box from the centring cases and turn toward
subframes, move the spindles of the gearbox support - 3282-
in the process.
Note
Observe coolant hose between engine and heat exchanger for

heater.
2.1.2 Installation permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Installation is carried out in reverse order, noting the following:

Note
♦ Clean the splines on the input shaft and lightly lubricate them
with grease ⇒ Spare Spare parts catalogue .
♦ The clutch plate should always be free to move on the input
shaft.
♦ Check if the dowel sockets for centering the gearbox with the
engine are fitted and damage free, if not replace them.
♦ Ensure that intermediate plate is correctly seated on engine.
♦ If the gearbox is replaced, the following must be reused in the
new gearbox: selection rod and the relay shaft.
♦ When fitting the pendulum support position the bolts in the
support holes so that there is a maximum distance between
the gearbox and the subframe.
♦ When the by
Protected battery
copyright.isCopying
reconnected, coding must
for private or commercial bein part
purposes, carried out is not
or in whole,
according to the
permitted unless fitted
authorised by equipment;
SEAT S.A. SEAT S.A enter
doesthe radio code,
not guarantee or acceptadjust
any liability with
the clock.
The remainder of the installation is carried out in the reverse order

of removal while noting the following:
– Assemble engine and gearbox support , gearbox support -
3282- , adjustment plate - T30020- for “02R” gearbox and
mounting elements as follows:
ment plate.
ment plate.
– Align gearbox parallel to adjustment plate and set on engine
and gearbox jack .
– Lock safety support to gearbox.
– Position engine and gearbox jack under vehicle. -Arrow B-

(figure above) on adjustment plate points in direction of vehicle
travel.
Note
When installing the gearbox, do not damage any cables or lines.
– Tilt gearbox further using spindles of gearbox support - 3282- .

• Differential area faces upwards.
• 5th gear area (sheet metal cover) faces downwards.

– Then carefully raise gearbox.
– Guide gearbox with differential over subframe.

– Swivel gearbox towards engine.
Right flange shaft -1- must be guided past bolt hole of engine
-2-.
– Lift gearbox in area of 5th gear (sheet metal cover) using spin‐
dle of gearbox support - 3282- .
– Move gearbox into installation position using spindles of gear‐
box support - 3282- .
– Install lower engine/gearbox securing bolts ⇒ page 65 .
– Insert heat shield -2- so that lower lug hooks onto engine block
and secure it at its upper part with bolt -1- .
– Install upper engine/gearbox securing bolts ⇒ page 65 .
– Fit gearbox bracket -A- with new bolts -arrows- ⇒ page 65 .

– Moisten bonded rubber mounting of left assembly mounting
and upper section of gearbox bracket with assembly lubrica‐
tion oil ⇒ Electronic parts catalogue (ETKA) .
– Centre engine assembly so as Protected
to bring it to theCopying
by copyright. correct instal‐
for private or commercial purposes, in part or in whole, is not
lation position. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

– Install new bolts -arrows- for left assembly mounting in gear‐

box mounting ⇒ page 65 .
– Install pendulum support with new bolts -arrows A- and

-arrow B- ⇒ Running gear, axles, steering; Rep. gr. 40 .
WARNING
Support bracket - 10-222 A- must not be removed until all bolts

on the assembly mountings have been tightened to specified
torque.
– Fit the complete half-shafts ⇒ Running gear, axles, steering;

Rep. gr. 40 .
– Install the drive shaft heat shield, if present -arrows- ⇒ Run‐

ning gear, axles, steering; Rep. gr. 40 .
– Push connector -arrow 3- onto reversing light switch - F4- .

– Fit the starter motor ⇒ Electrical system; Rep. gr. 27 .
– Connect wire -arrow 2- to starter and mount the guard cap ⇒
Electrical system; Rep. gr.Protected
27 . by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Push on starter connector -arrow 1-.
Vehicles with start / stop system

– Connect the connector -arrow- of the gearbox neutral position

sender - G701- .
– Install pipe -B- and hose -C- of the charged air cooler. Tighten
the metal flange and screw the bottom fixing nuts of the charg‐
ed air cooler -A- pipe tight.
– Screw the upper securing bolt of the plastic tube of the charged
air cooler -2- tight and tighten the metallic flange of its upper
sleeve.
– Screw the fixing screws of the earth cable -1- tight.
– Install slave cylinder -arrows-.

– Press pipe/hose line -A-, if present, into retainer -B- on gear‐

box.
– Install cable support bracket on gearbox and tighten bolts
-arrows- to specified torque ⇒ Item 9 (page 43) .
– Install gearbox selector lever -A- and tighten the gearbox se‐
lector lever -arrow 2- to the respective tightening torque
⇒ Item 10 (page 43) .
– Install the new safety washer -arrow 1- that secures the con‐
nector cable to selector rod.
– Fit the idler rod ⇒ page 45
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Adjust selector mechanism ⇒ page 49 .
– Check the gear oil ⇒ page 81 .
– Install the front left wheel housing: ⇒ Bodywork, exterior fitting
work; Rep. gr. 66 .
– Install noise insulation tray ⇒ General body repairs, exterior;
Rep. gr. 50 .
– Fit the battery holder, the cover of the battery and the battery
itself ⇒ Electrical system; Rep. gr. 27 .
– Install battery and battery holder: ⇒ Electrical system ; Rep.
gr. 27 .
– Observe the procedures after connecting the battery ⇒ Elec‐
trical system; Rep. gr. by27
Protected .
– Install air cleaner housing ⇒ correctness
respect to the Rep. gr.of information
23 . in this document. Copyright by SEAT S.A.
Note
Note radio code for vehicles with coded radio.

2.1.3 Tightening torque

Gearbox to engine
Item Bolt Qty. Nm
1 M12 x 50 2 80
2 M12 x 150 2 80
♦ Additionally, start‐
er to gearbox
3 M10 x 50 3 40
4 M12 x 60 1 80
5 M6x8 1 10
♦ Small flywheel
cover plate
Pos. -A- Adjusting sleeves for centring.

Gearbox bracket -1- to gearbox. respect to the correctness of information in this document. Copyright by SEAT S.A.
– Renew bolts
– Tighten all bolts hand-tight.
– Tighten bolt -A- to specified torque.
– Tighten bolts -B- to specified torque.
Item Bolt Qty. Nm
A M10 x 40 1 40 + 90°
B M10 x 52 2 40 + 90°
Gearbox to bodywork
– Renew bolts
– Tighten bolts -arrows- to specified torque.
Bolts -arrows-: 40 Nm + 90°
Note
Install the subframe free of stress ⇒ Repair group 10; Removing

and installing engine .
Slave cylinder to gearbox ⇒ Item 12 (page 25)

Gearbox selector lever to selector shaft ⇒ Item 10 (page 43) .
Pendulum support to subframe and gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40 .
Driveshaft to the flanged shaft ⇒ Running gear, shafts, steering;
Rep. gr. 40 .
Ball joint on the strut ⇒ Running gear, axles, steering; Rep. gr.
40 .

2.2 Removing and installing gearbox: Tole‐

do 2013 ►
⇒ “2.2.3 Tightening torque”, page 79

equipment required
♦ Rear bracket - 10 222A-
♦ Hook - 10 222A/10-
♦ Engine bracket supplement
- 10 222A/31-
♦ Engine bracket, basic set -
T40091- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Shackle - 10-222 A/12-

♦ Adjustment plate - T30020-

♦ Engine/gearbox jack -
V.A.G 1383 A-
V.A.G 1331-
V.A.G 1332-
- 3282-
♦ Support elements for gear‐
box (determine when set‐
ting adjustment plate on
gearbox support )
♦ Studs - 3282/29-
♦ Gearbox lifting tackle -
3336- for transporting gear‐
box
♦ Allocate grease using ⇒
Electronic parts catalogue
(ETKA) .
2.2.1 Detaching
– The vehicle should be checked if a coded radio is fitted in the
vehicle. If necessary obtain radio anti-theft code first.
– With ignition switched off, disconnect battery earth strap.
– Remove engine cover
permitted ⇒ authorised
unless engine;by Rep.
SEAT S.A.gr.SEAT
10S.A. does not guarantee or accept any liability with

– Remove the vacuum lines with the bracket -1- from the air filter
and disconnect the plug -3- -direction of arrow-.
– Unscrew the charge pressure control solenoid valve - N75-
with bracket -2- -arrow- and put aside correctly.
– Remove the battery as well as its cover and mount ⇒ Electrical
system; Rep. gr. 27 .
– Remove the air filter housing completely with air hose ⇒ Rep.
gr. 23 .

– Remove plenum chamber cover ⇒ Rep. gr. 66 .

– Remove rubber mounting -arrow 2- of vacuum hose from re‐
taining eye on engine.
– Detach the fastening element from the selector cable

⇒ page 45
– Remove the clip -arrow 1- and remove the relay lever together
with the fixing elements of the cable.
Note
Relay lever is secured with a catch in some vehicles ⇒ page 45 .
– Remove the safety washer -arrow 2- that secures the connec‐

tor cable to selector rod -A-.
– Remove the connector cable from the pivot.
– Remove gearbox selector lever -A- by removing nut
-arrow 3-.
– Remove the control cable counter supports from the gearbox

-arrows-
– Then raise and secure gear selector cable and gate selector
cable.
– Remove bracket -B-, if present, from gearbox and pull it off
pipe/hose line -A-.
– Remove slave cylinder -arrows-, lay to side and secure. Do

not disconnect pipes.
Caution
Do not operate clutch pedal after disconnecting pipe/hose as‐

sembly.
– Unscrew the upper bolts that secure the engine to the gearbox.

– Remove connector -arrow 1- from starter.

– Now remove deflector cap -arrow 2- from starter.
– Then remove line from starter.
– Unplug connector from reversing light switch - F4- -arrow 3-.
– Gearboxes for vehicles with start-stop system: release con‐

nector -arrow- of the gearbox neutral position sender - G701- .
– Remove nut -arrow- and remove retainer for electrical lines.

– Removing the starter motor⇒ Electrical system; Rep. gr. 27 .
– When hose and cable connections are located close to engine
lifting eyes for support bracket - 10-222 A- , they must now be
removed.
Preparing the engine bracket supplement - 10 222A/31-4- :

– Remove both fixing pins -1- of the engine bracket supplement
- 10 222A/31-4- .
Note
The top layer of the lock carrier does not have to be removed.

– Place the Adapter - 10-222 A /31-4- -1- centred on the mount

of the lock -2-.
– Install the support bracket - 10 - 222 A- as shown in the figure.

1- attachment tool - 10-222 A /31-2-
2- Adapter - T40091/3-
3- attachment tool - 10-222 A /31-1-
4- Rod - T40091/1-
5- Adapters - 10-222 A /31-4-
6- Adapter - 10-222 A /31-3-
– Attach the shackle - 10-222 A/12- to the back of the engine.
Caution
Make sure vacuum hose can move freely -arrows-.

It must not be damaged.
– Then connect shackle - 10-222 A/12- to support bracket.

– Take up weight of engine/gearbox assembly via the spindles.
– Separate the front section of the exhaust system at double
clamp and remove from the subframe ⇒ Rep. gr. 26 .
– Remove the front left wheel housing: ⇒ Bodywork, exterior
– Remove pendulum support -arrows A- and -B-.

– Remove left-hand articulated shaft: ⇒ Running gear, shafts,
steering; Rep. gr. 40 .

– Remove drive shaft heat shield, if present -arrows- ⇒ Running

gear, axles, steering; Rep. gr. 40 .
– Remove drive shafts from the gearbox and tie-up ⇒ Running
– Locate subframe in position ⇒ Running gear, axles, steering;
Rep. gr. 40 .
– If small cover plate -A- for flywheel is present, remove it

-arrows-.
– Remove hexagon bolts -arrows- at left mounting from gearbox
mounting.
– Lower the gearbox by about 55 mm to dimension -a-.

– Lower engine somewhat as well.

Vacuum hose -arrows- must not be trapped
Caution
Retaining eye of engine is not allowed to touch brake fluid res‐

ervoir and brake lines.
• Securing bolts -arrows- for gearbox bracket -A- must be ac‐

cessible.
– Remove gearbox bracket -A- -arrows-.
– Remove lower engine/gearbox connecting bolt -1-.
Note permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Loosen engine/gearbox connecting bolt -3- and leave it installed

just hand-tight.
Assemble engine and gearbox support , gearbox support - 3282- ,

adjustment plate - T30020- for “02R” gearbox and mounting ele‐
ments as follows:
ment plate.

ment plate.
– Screw in the bolts - 3282/29- as displayed on the adjustment
plate.

– Position engine and gearbox jack under vehicle. Arrow -B- on

adjustment plate points in direction of vehicle travel.
– Align adjustment plate parallel to gearbox and lock safety sup‐
port on gearbox.
– Push the gearbox off the dowel sleeves and swing carefully
towards the subframe.
• Differential must face upwards.
– Guide gearbox with differential over sub frame -A- and swing
out.
– If necessary, turn gearbox further upwards near differential
– Swivel gearbox further out and carefully lower.

– Turn gearbox down in area of 5th gear (sheet metal cover)
– Move the position of the gearbox downwards using spindles
of gearbox support - 3282- .
Note
Observe coolant hose between engine and heat exchanger for

heater.
2.2.2 Installation
– Clean splines of input shaft and apply a thin coat of grease -
G000 100- .
The clutch plate must slide easily to and fro on the input shaft.
– Check if the centring sleeves are installed in the engine for the
purpose of centring the engine with the gearbox and insert
these if they are not installed.

– Ensure that intermediate plate is correctly seated on engine.

– Assemble engine and gearbox support , gearbox support -
3282- , adjustment plate - T30020- for “02R” gearbox and
mounting elements as follows:
ment plate.
ment plate.
– Align gearbox parallel to adjustment plate and set on engine
and gearbox jack .
– Lock safety support to gearbox.
– Position engine and gearbox jack under vehicle. -Arrow B-

(figure above) on adjustment plate points in direction of vehicle
travel.
Note
When installing the gearbox, do not damage any cables or lines.
– Tilt gearbox further using spindles of gearbox support - 3282- .

• Differential area faces upwards.
• 5th gear area (sheet metal cover) faces downwards.
– Then carefully raise gearbox.

– Guide gearbox with differential over subframe.

– Swivel gearbox towards engine.
Right flange shaft -1- must be guided past bolt hole of engine
-2-.
– Lift gearbox in area of 5th gear (sheet metal cover) using spin‐
dle of gearbox support - 3282- .
– Move gearbox into installation position using spindles of gear‐
box support - 3282- .
– Install lower engine/gearbox securing bolts ⇒ page 79 .
– After gearbox has been bolted to engine, remove engine and
gearbox jack from gearbox.
– If fitted, install the small cover plate -A- at rear of flange shaft
(right-side) -arrows- ⇒ page 79 .
– Install upper engine/gearbox securing bolts ⇒ page 79 .
– Fit gearbox bracket -A- with new bolts -arrows- ⇒ page 79 .

– Moisten bonded rubber mounting of left assembly mounting
and upper section of gearbox bracket with assembly lubrica‐
tion oil ⇒ Electronic parts catalogue (ETKA) .
– Centre engine assembly so as to bring it to the correct instal‐
lation position.
– Install new bolts -arrows- for left assembly mounting in gear‐

box mounting ⇒ page 79 .
– Install earth strap at upper engine/gearbox connecting bolt or
at assembly mounting on right.
– Lift and fix the subframe ⇒ Running gear, axles, steering; Rep.
gr. 40 .

– Install pendulum support with new bolts -arrows A- and

-arrow B- ⇒ Running gear, axles, steering; Rep. gr. 40 .
WARNING
Support bracket - 10-222 A- must not be removed until all bolts

on the assembly mountings have been tightened to specified
torque.
– Fit the complete half-shafts ⇒ Running gear, axles, steering;

Rep. gr. 40 .

– Assemble exhaust system ⇒ Rep. gr. 26 .
– Push connector -arrow 3- onto reversing light switch - F4- .

– Fit the starter motor ⇒ Electrical system; Rep. gr. 27 .
– Connect wire -arrow 2- to starter and mount the guard cap ⇒
Electrical system; Rep. gr. 27 .
– Push on starter connector -arrow 1-.
– Gearboxes for vehicles with start-stop system: push connector

-arrow- on the gearbox neutral position sender - G701- .

– Install slave cylinder -arrows-.
– Install vacuum hose -arrow 1- ⇒ Rep. gr. 47 .

– Press rubber mounting -arrow 2- of vacuum hose into retaining
eye on engine.
– Press pipe/hose line -A-, if present, into retainer -B- on gear‐

box.
– Install cable support bracket on gearbox and tighten bolts
-arrows- to the respective tightening torque

– Install gearbox selector lever -A- ⇒ page 44 .

– Tighten hexagon nut -arrow 3- to specified torque
⇒ Item 10 (page 43) .
– Spread a small amount of grease on pin of gearbox selector
lever -A-.
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Connect gear selector cable to gearbox selector lever.
– Renew securing clip -arrow 2- each time it is removed.
– Install relay lever together with cable end-piece ⇒ page 45 .
• Clip -arrow 1- secures the relay lever.
• Ensure proper engagement of clip.
Note
Relay lever is secured with a catch in some vehicles ⇒ page 45 .
– Join the selector cable with the cable fastener.

– Adjust selector mechanism ⇒ page 49 .
– Check the gear oil ⇒ page 81 .
– Install the front left wheel housing: ⇒ Bodywork, exterior fitting
work; Rep. gr. 66 .
– Install noise insulation tray ⇒ General body repairs, exterior;
Rep. gr. 50 .
– Fit the battery holder, the cover of the battery and the battery
itself ⇒ Electrical system; Rep. gr. 27 .
– Install battery and battery holder: ⇒ Electrical system ; Rep.
gr. 27 .
– Observe the procedures after connecting the battery ⇒ Elec‐
trical system; Rep. gr. 27 .
– Install the air filter housing completely with air hose ⇒ Rep.
gr. 23 .
Note
Note radio code for vehicles with coded radio.

2.2.3 Tightening torque

Gearbox to engine
Item Bolt Qty. Nm
1 M12 x 50 2 80
2 M12 x 150 2 80
♦ Additionally, start‐
er to gearbox
3 M10 x 50 3 40
4 M12 x 60 1 80
5 M6x8 1 10
♦ Small flywheel
cover plate
Pos. -A- Adjusting sleeves for centring.
Gearbox bracket -1- to gearbox.

– Renew bolts
– Tighten bolt -A- to specified torque.
– Tighten bolts -B- to specified torque.
Item Bolt Qty. Nm
A M10 x 40 1 40 + 90°
B M10 x 52 2 40 + 90°
Gearbox to bodywork
– Renew bolts
– Tighten bolts -arrows- to specified torque.
Bolts -arrows-: 40 Nm + 90°
Note
Install the subframe free of stress ⇒ Repair group 10; Removing

and installing engine .
Slave cylinder to gearbox ⇒ Item 12 (page 25) .

Gearbox selector lever to selector shaft ⇒ Item 10 (page 43) .
– Subframe ⇒ Running gear, axles, steering; Rep. gr. 40 .
Pendulum support to subframe and gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40 .
Driveshaft to the flanged shaft
permitted ⇒ authorised
unless Running gear,
by SEAT S.A.shafts,
SEAT S.Asteering;
does not guarantee or accept any liability with
Rep. gr. 40 . respect to the correctness of information in this document. Copyright by SEAT S.A.
Ball joint on the strut ⇒ Running gear, axles, steering; Rep. gr.
40 .
Double clamp to the exhaust tube ⇒ Rep. gr. 26 .

3 Transporting gearbox
– Bolt gearbox lifting tackle - 3336- to clutch housing.
– Adjust support beam on sliding piece using locking pin
-arrow-. respect to the correctness of information in this document. Copyright by SEAT S.A.
Number of holes visible = 5

– Take up gearbox with workshop hoist and gearbox lifting tack‐
le - 3336- .
– Set gearbox aside, for example in a transport container.

4 Gear oil level

⇒ “4.1 Check and refill”, page 81
⇒ “4.2 Renew”, page 81
4.1 Check and refill

– Raise the vehicle
– Loosen oil level test bolt -arrow-.
Note
Oil level is correct when the oil reaches the bottom edge of filling
hole.
Oil specification for gears ⇒ page 7 .

– If the oil level is not correct, complete oil level.
– Unscrew control lid, start engine and let the gears work with
engaged gear for about 2 minutes.
– Stop the engine, remove oil cap and check level again, top up
if necessary.
– Tighten the gearbox oil level control cap to a torque of 25 Nm.
– Install the middle soundproofing.
4.2 Renew
– Raise the vehicle
– Unscrew drain plug -arrow- and empty gearbox oil.
4. Gear oil level 81

– Unscrew oil level test and filler plug -arrow-.

– Tighten the gearbox oil discharge cap to a torque of 25 Nm.
Note
Oil level is correct when the oil reaches the bottom edge of filling
hole.
Oil specification for gears ⇒ page 7 .

– Fill with new gear oil up to the correct level.
– Unscrew control lid, start engine and let the gears work with
engaged gear for about 2 minutes.
– Stop the engine, remove oil cap and check level again, top up
if necessary.
– Tighten the gearbox oil level control and filler cap and tighten
to a torque of 25 Nm.
– Install the middle soundproofing.

5 Gearbox: disassembly and assembly

⇒ “5.1 Overview - gearbox”, page 83
⇒ “5.2 assembly overview”, page 84
⇒ “5.3 Assembly overview - removing and installing cover for
gearbox housing and 5th gear”, page 85
⇒ “5.4 Removing and installing gearbox housing and selector
mechanism - Assembly overview”, page 86
⇒ “5.5 Removing and installing input shaft, output shaft, differen‐
tial and selector rods - Assembly overview”, page 87
⇒ “5.6 Assembly sequence - removing and installing cover for
gearbox housing and 5th gear”, page 88
⇒ “5.7 Assembly sequence - Dismantling and assembling gear‐
box completely”, page 94
5.1 Overview - gearbox
1 - 1. th gear
2 - 2. th gear
3 - 3. th gear
4 - 4. th gear
5 - 5. gear
6 - Gearbox
❑ Repairing ⇒ page 109
7 - Selector mechanism
❑ (Selector forks)
❑ Dismantling and assem‐
bling ⇒ page 121 .
8 - Input gear for 1st speed se‐
lector gear and reverse gear
9 - Drive shaft Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

10 - Output shaft
12 - Clutch housing
5. Gearbox: disassembly and assembly 83

5.2 assembly overview
I - Assembly overview - remov‐

ing and installing cover for
gearbox housing and 5th gear
⇒ page 85
II - Removing and installing
gearbox housing and selector
mechanism - Assembly over‐
view ⇒ page 86
III - Assembly overview - re‐
moving and installing input
shaft, output shaft, differential
and selector forks
⇒ page 87
Assembly sequence - remov‐
ing and installing cover for
gearbox housing and 5th gear
⇒ page 88 .
Mounting sequence - com‐

pletely disassembling and as‐
sembling the gearbox
⇒ page 94

5.3 Assembly overview - removing and installing cover for gearbox housing and
5th gear
❑ To secure the cover on
the gearbox casing
2 - Gearbox housing cover
❑ From 11.10 with magnet
⇒ page 86
Note
If gearbox housing cover is removed

and installed with gearbox installed,
check oil level and top up with gear
oil ⇒ page 81 .
3 - Gasket
4 - Bolt, 80 Nm + turn 90° fur‐
ther
❑ Always replace
❑ Holds plate spring in
correct position with ad‐
justment section of bolt
head
❑ Clean residual locking
fluid from threaded
holes for synchro-hub
securing bolts and 5th
gear wheel with a thread
chaser. Otherwise bolts
can break.
5 - Dished washer
6 - Socket head bolt, 25 Nm
❑ For mounting bearing
pin on transmission
housing
7respect
- Pivot pin
to the correctness of information in this document. Copyright by SEAT S.A.
8 - 5th gear selector fork

❑ Dismantling and assembling ⇒ page 121 .
9 - Spring
10 - Locking collar for 5th gear
❑ Adjusting ⇒ page 108
11 - Locking pieces (3 off)
12 - Synchronising hub with 5th speed selector gear and synchro-ring
❑ Remove together with the gearbox housing ⇒ page 94
❑ Remove individually ⇒ page 88

13 - Gear needle roller bearing

14 - 5th gear pinion
Cover for gearbox housing with magnet -A-

The magnet can only be attached in covers with a recess
-arrow-.
When the cover is mounted, the magnet will be kept in position
by the fixing screw for the bearing pinion of the gear prong for 5th
gear.
5.4 Removing and installing gearbox housing and selector mechanism - As‐
sembly overview
1 - Countersunk bolt, 25 Nm
2 - Flange shaft with compres‐
sion spring
⇒ page 157
❑ Assembling
⇒ page 166
3 - Torx socket head bolt, 25
Nm
❑ For reverse shaft sup‐
port
❑ Self-locking
❑ Always replace
Nm
❑ For reverse shaft sup‐
port
❑ Self-locking
❑ Always replace
5 - O-ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Always replace respect to the correctness of information in this document. Copyright by SEAT S.A.
6 - Pivot pin
7 - Bolt, 25 Nm
8 - Bolt, 25 Nm
9 - End cover
10 - Gearbox
❑ Pull off together with 5th
gear ⇒ page 94

11 - Bolt, 5 Nm
12 - Gearbox neutral position sender - G701-
❑ For vehicles with start stop system
13 - Clutch housing
14 - Hexagon bolt, 25 Nm and turn 90° further
❑ Always replace
15 - Gear selection mechanism
5.5 Removing and installing input shaft, output shaft, differential and selector
rods - Assembly overview
❑ Dismantling andauthorised
assem‐by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted unless
bling ⇒ page 166
respect . correctness of information in this document. Copyright by SEAT S.A.
to the
2 - Oil seal
❑ 4 off
❑ Always replace
3 - Output shaft
4 - Reverse shaft support
bling
⇒ Item 8 (page 155) .
5 - Reverse gear shaft:
6 - Drive shaft
7 - Selector fork for reverse
gear
⇒ page 103
Nm
9 - Gear selection mechanism
❑ (Selector forks)
10 - Clutch housing
11 - Hexagon nut, 25 Nm and turn 90° further
❑ 4 nuts for bearing support

❑ Always replace
12 - Flange shaft with compression spring
❑ Assembling ⇒ page 166
5.6 Assembly sequence - removing and in‐

stalling cover for gearbox housing and
5th gear
Note
♦ Follow the working procedure described below if only the 5th

gear has to be removed:
♦ If the gearbox housing must be removed, the following work
sequence is to be taken into account: Completely disassem‐
bling and assembling the gearbox ⇒ page 94 .


equipment required
♦ Retaining plate - VW 309-
♦ or support plate - VW 309
A-
- VW 353-
♦ Mandrel - VW 295-
♦ Drift sleeve - VW 244 B-
♦ e.g. hot-air blower - V.A.G
1416-
V.A.G 1331-
♦ -Stehbolzen M 8 x 100 mm-

♦ Support bridge - 30-211A-

♦ Insertion tool - 32 - 111-
♦ Thrust piece from assembly
tool - T10030/4-
♦ Tube element - VW 416 B-
♦ Puller - T10309-
♦ Two arm puller - T10040-
♦ With puller hooks -
T10040/2A-

♦ Support bridge - T10323-

♦ Assembly tool - 3253/7-
♦ Thrust pad - VW 433-
♦ Pressure plate - 40 - 105-
♦ Torque wrenches - V.A.G
1332-
♦ Tray - V.A.G 1306-
♦ or drip tray for workshop
hoist - VAS 6208-
5.6.1 Detaching
– Remove clutch release lever and release bearing ⇒ page 32 .
• Bearings of input shaft and output shaft must not be damaged
when 5th gear is re-installed.
• Therefore, following tools must be mounted for support at this
stage during attachment of gearbox to gearbox support - VW
353- :
Underneath input shaft:
♦ Thrust pad - T10030/4-
•permitted
Theunless
inputauthorised
shaft can beS.A.
by SEAT supported
SEAT S.A doesby not
theguarantee
thrustorpiece - 32
accept any - 111-
liability with
only at ato the
respect later point.of information in this document. Copyright by SEAT S.A.
correctness
Underneath bearing support for output shaft:


– Secure gearbox on gearbox support - VW 353- .
– Unscrew the gearbox casing cover -arrow-.
– Check whether puller hooks - T10040/2A- can be inserted

correctly under 5th gear wheel.
Puller hooks - T10040/2A- cannot be inserted correctly.
-A- Removing the “unit ”: “syn‐
Puller hooks - T10040/2A- make chro-hub for 5th gear”,
contact too soon with: “gear wheel for 5th gear”
♦ gearbox housing wall and “gearbox housing”
⇒ page 94
♦ the ribs of the gearbox housing
under the pinion
-B-
Puller hooks - T10040/2A- come
into contact withunless
ribsauthorised
in gearbox
permitted by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
housing below gear
respect to thewheel.
correctness of information in this document. Copyright by SEAT S.A.
Puller hooks - T10040/2A- cannot be inserted correctly.

5th gear can be removed separately
Removing 5th gear separately

– Remove selector fork for 5th gear as follows:
– Cover openings with a cloth.
– Move selector fork -1- to neutral.
– Then remove both bolts -2- for pivot pins.
– Pull out pivot pins -direction of arrow A-.
– Remove selector fork -direction of arrow B-.

– Remove bolts -A- for synchro-hub and gear wheel for 5th gear.
To do this, engage 5th gear -arrow 1- and 1st gear
-arrows 2- and -3-.
– After both gears are engaged, the input shaft and output shaft
are locked. The synchro-hub and gear wheel cannot turn. Now
the two bolts can be loosened.
Note
If shafts are not to be renewed, carefully clean residual locking

material out of the tapped holes using a thread tap.
Pulling off synchronising hub for 5th gear together with locking
collar and locking pieces
Use puller - T10309- .
– First set half sleeve - T10309/1- between 5th gear wheel -A-
and support for selector fork for 5th gear -B-.
• Shell half - T10309/1- must be positioned underneath synchro-

ring.
– If necessary, half sleeve must be pressed to end position.
– Then turn shell half - T10309/1- to opposite side in direction of
-arrow-.
– Set threaded insert - T10309/3- in half shell .

– Now fit second half shell - T10309/1- and set tube - T10309/2-
over assembly.
– Please check synchronising hub for damage after removal.
– Renew synchro-ring.
– Remove 5th speed selector gear with needle bearing.

– Pull off gear wheel for 5th gear.

– First set up puller hooks -A-.
B - Hexagon bolt M10 x 20, 17 mm AF
Note
When pulling off gear wheel, ensure that hooks do not bend out‐
wards. After pulling off 5th gear wheel, examine for damage.
5.6.2 Installation
Fit 5th gear ⇒ page 106
– Apply sealant - AMV 188 200 03- evenly to sealing surface of
gearbox housing cover.
– Fit the gearbox casing cover ⇒ page 85 .
– Install clutch release lever and release bearing ⇒ page 32 .
– Fill up gear oil ⇒ page 81 .
5.7 Assembly sequence - Dismantling and

assembling gearbox completely
⇒ “5.7.3 Installing 5th gear”, page 106
Removing and installing gearbox housing cover, gearbox hous‐
ing, selector shaft with selector mechanism cover,
Protected by copyright. input
Copying shaft,
for private or commercial purposes, in part or in whole, is not
output shaft, differential and selector mechanism.


equipment required
A-
- VW 353-
1416-
V.A.G 1331-


equipment required
A-
- VW 353-
1416-
V.A.G 1331-


♦ Thrust piece from assembly
tool - T10030/4-
♦ Tube element - VW 416 B-
♦ Puller plate - T10408-
♦ Spacers - T10408/1-
♦ Thrust pieces - T10408/2-
♦ Grips - T10408/3-
♦ Hexagon bolts M7 x 35 with
washers
♦ Puller - 2 Kukko 18/1-


1332-
♦ Tray - V.A.G 1306-
hoist - VAS 6208-
5.7.1 Detaching
– Remove clutch release lever, release bearing and guide
sleeve ⇒ page 32 .
• Bearings of input shaft and output shaft must not be damaged
when 5th gear is removed and installed.
• Therefore, following tools must be mounted for support at this
stage during attachment of gearbox to gearbox support - VW
353- :
Underneath input shaft:
♦ Thrust pad - T10040/3-
– Secure bolt of support bridge - 30-211A- with lock nut -A-.
Underneath bearing support for output shaft:

– Secure gearbox on gearbox support - VW 353- .

– Place below the collecting tray - V.A.G 1306- .
– Unscrew oil filler plug and oil drain plug.
– Drain gear oil.
– Unscrew the gearbox casing cover -arrow-.
Remove selector fork for 5th gear as follows:

– Cover openings with a cloth.
– Move selector fork -1- to neutral.
– Then remove both bolts -2- for pivot pins.
– Pull out pivot pins -direction of arrow A-.
– Remove selector fork -direction of arrow B-.
– Remove bolts -A- for synchro-hub and gear wheel for 5th gear.
To do this, engage 5th gear -arrow 1- and 1st gear
-arrows 2- and -3-.
are locked. The synchro-hub and gear wheel cannot turn. Now
the two bolts can be loosened.
Note
If shafts are not to be renewed, carefully clean residual locking

material out of the tapped holes using a thread tap.

– Remove both bolts -arrows- for reverse shaft support bracket.
– Gearboxes for vehicles with start-stop system: remove gear‐

box neutral position sender - G701- -arrow-.
– Remove selector shaft with selector mechanism cover, placing

selector shaft in neutral position. Then unscrew the bolts
-arrows- and remove the selector shaft from the gearbox cas‐
ing.
– Remove cover plate -A- and pivot pins -B- from underside of
gearbox.

– Remove pivot pins -A- on top side of gearbox and securing

bolts -B- for gearbox housing to clutch housing in area of dif‐
ferential.
– Remove bolts -A- from clutch housing side for securing clutch
housing to gearbox housing.
Note
Do not remove nuts -B- for output shaft bearing support.
– Remove both flange shafts.

– Take out flange shafts together with springs, thrust washers
and tapered rings.
Pull off following components together with gearbox housing:

♦ Synchro-hub for 5th gear
♦ 5th gear pinion
• Both grips - T10408/3- must be secured on gear wheel for 5th
gear.
• The grips must always be positioned above the two housing
ribs, which are located opposite each other -arrows-.
Note
♦ There is a needle bearing beneath the gearunless
permitted wheel for 5th
authorised gear.
by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Secure the grips so that the bearing does not come in contact
with the gear wheel for 5th gear when the gearbox housing is
pulled off.

Use puller plate - T10408- in conjunction with following special

tools:
♦ Spacers - T10408/1-
♦ Thrust pieces - T10408/2-
♦ Grips - T10408/3-
♦ Pullers Kukko 18/1
– Screw 5 spacers - T10408/1- firmly into threaded holes for
gearbox housing cover.
– Screw puller plate - T10408- firmly onto spacers - T10408/1- .
A - Hexagon bolts M7 x 35 with washers
Tightening torque: 18 Nm
– Place thrust pieces - T10408/2- on shafts.

– Install puller Kukko 18/1 .
– Pull off the synchro-hub for 5th gear, gear wheel for 5th gear
and the gearbox housing by alternately pressing the worm
gear -A- - (approx. 12 revolution).
– Heat gear wheel for 5th gear slightly with hot air blower -
V.A.G 1416- if necessary.
– Remove selector forks -A- together with selector plates.

– Unscrew bolt for reverse gear selector mechanism -B-.
– Remove nuts -B- for output shaft bearing support.


– Remove reverse gear -A-, input shaft -B- and output shaft
-C- one after the other from clutch housing.
– Remove differential.
5.7.2 Installation
– Install differential.
– Always renew sealing rings -arrows- for output shaft bearing
support.
Note
The figure shows only 3 of the 4 sealing rings.
– Insert input shaft -1- and output shaft -2- together.

– Tighten the nuts and the bearing support of the differential
gearbox to the respective tightening torque
⇒ Item 11 (page 87) . permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Place the mobile pinion for reverse gear -3- onto the needle
bearing of the clutch housing.
The groove -arrow- should face away from the clutch housing.
– Ensure that reverse shaft -4- is complete ⇒ page 154 ; do not
yet fit reverse shaft support to reverse shaft.
– Fit the reverse shaft into clutch housing.
– Clean all locking fluid away from all threaded holes in reverse
shaft support; a thread cutter may be used for this purpose.
– Install reverse shaft support.
– Mount the gear prong of the reverse gear -1- with the support
for the gear prong of the reverse gear -2-, the spring -3- and
the slide -4-.

Installation position: reverse gear
– Bolt on reverse gear selector mechanism -B-, tightening to

specified torque ⇒ Item 8 (page 87) .
– Install the gear prong -A- along with the selector plates.
– Screw M8 x 100 mm
stud -A- into reverse shaft support so that shaft is aligned after
gearbox housing is fitted.
– Align selector plates.
Note
The selector segments must

Protected be positioned
by copyright. in theor grooves
Copying for private on thein part or in whole, is not
commercial purposes,
locking collars. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Apply sealant -AMV 188 200 03- evenly to sealing surface of

clutch housing.
– Fit gearbox housing.
Insert the bolts for reverse gear shaft support -arrow- as shown:
– Fit bolt -a-.
– Remove stud -A- (⇒ figure above).
– Install bolt -b- and tighten by hand.
Tightening sequence:
1- Bolt -a- 30 Nm
2- Bolt -b- 25 Nm

– Install the bearing pin -arrow- for the gear prongs. To do this
align selector mechanism using a screwdriver so that the rel‐
evant pivot pin can be inserted.
cover plate.
– Fit selector shaft cover.
Install the gear lever as described in the following:

– Place the gearshift lever in neutral position.
– Locate lug -arrow 1- in recess in gearbox housing. Position
selector shaft so that selector finger -arrow 2- is engaged in
selector plates.
selector mechanism cover.
– Install selector mechanism cover ⇒ page 86 .
– Gearboxes for vehicles with start-stop system: install gearbox

neutral position sender - G701- -arrow- and tighten the bolt to
the corresponding tightening torque ⇒ Item 11 (page 87) .
– Install both flange shafts with compression springs, thrust

washers and tapered rings ⇒ page 84 .
– Fit release bearing guide sleeve ⇒ page 32 .
– Install clutch release lever and release bearing ⇒ page 32 .

5.7.3 Installing 5th gear

• Ensure that support bridge - 30-211A- and support device -
T10323- are installed.
– Secure bolt of support bridge - 30-211A- with lock nut -A-.
Installation position of 5th gear wheel

The groove running round the gear wheel -arrow- faces to the
gearbox housing.
– Pressing on gear wheel for 5th gear
Checking 5th gear synchro-ring

– Before re-installing selector gearunless
permitted andauthorised
synchro-ring
by SEAT S.A.forSEAT S.A does not guarantee or accept any liability with
5th gear, press the synchro-ring onto the tapered seat of the
selector gear and measure gap -a- with a feeler gauge.

Gap -a- Installation dimen‐ Wear limit
sion
5. gear 1.1 … 1.7 mm 0.5 mm
– Install 5th gear synchromeshed gear with needle bearing.
– Fit 5th gear synchro ring on the mobile pinion.
– Assemble 5th gear synchronising hub/locking collar before in‐
stalling ⇒ page 132 .

Installation position 5th gear synchro-hub and locking collar

The pointed teeth of the locking collar -arrow 1- and the high
shoulder of the synchronising hub -arrow 2- face the gearbox
housing.
The supports -arrow 3- for the synchro-hub align with the cast
locking pieces of the gear synchro-ring (-arrows- in figure below).
5th gear synchro-ring with cast locking pieces -arrows-

– Cover all holes with rag to prevent foreign body from pene‐
trating into the transmission.
– Knock on 5th gear synchronising hub.
Note
When driving on, ensure clearance forProtected

synchro-ring.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Loosen support for input shaft.
WARNING
Wear protective gloves!
Clean residual locking fluid from threaded holes for securing bolts
-A- for synchro-hub for 5th gear and 5th gear wheel with a thread
chaser. Otherwise there is a risk that the bolts will shear off.
– Screw in securing bolts for synchronising hub and 5th gear
wheel.

Installation position of dished springs for securing bolts for 5th

gear wheel and synchronising hub
The outer diameter -arrows- faces 5th gear.
– Tighten securing bolts for synchro-hub and gear wheel for 5th
gear to specified torque ⇒ page 85 .
– Tighten bolts -A- for synchro-hub and 5th gear wheel to speci‐
fied torque ⇒ page 85 . To do this, engage 5th gear
-arrow 1- and 1st gear -arrows 2- and -3-.
are locked. The synchro-hub and gear wheel cannot turn. The
two bolts can now be tightened.
– Install 5th gear selector fork.
Adjusting 5th gear

– Select 5th gear. Loosen bolt -1-. Press the mobile sleeve and
the gear mouth in the direction of the -arrow-; then tighten the
bolt -1- to 25 Nm.
• Control measurement: Between the mobile sleeve and the
mobile pinion, a thickness gauge of 0.2 mm cannot be inser‐
ted. If necessary, repeat the adjustment process.
– Deselect 5th gear. Locking collar must now be in the neutral
position. Synchro-ring must move freely.
– Shift through all gears.
– Fit the gearbox casing cover ⇒ page 85 .

6 Gearbox casing and clutch housing: repairs

equipment required
♦ Adapter - VW 295 A-
♦ Pressure disk - VW 447 H-
♦ Pressure disk - VW 512-
♦ Tube element - 2040-
6. Gearbox casing and clutch housing: repairs 109


- VW 353-
♦ Spindle from assembly tool
- 3066-
♦ Seal and sleeve for right
flange shaft are two parts:
♦ Thrust pad - 3124-
♦ Seal and sleeve for right
flange shaft are one part:
♦ Universal tool - VW 771-
♦ Extraction hook -
VW 771/37-
♦ Thrust pad - T10148-

1 - Gearbox housing
❑ If renewed: adjust input
shaft and differential
⇒ page 165
❑ For secondary shaft
❑ Pressing out
⇒ page 112
❑ Driving in and securing
⇒ page 112
3 - Oil filler plug, 35 Nm
4 - Tapered roller bearing outer
race
⇒ page 129
❑ If replaced, adjust the
output shaft
⇒ page 133Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Shim
❑ Adjustment overview
⇒ page 165
6 - Shim
❑ For input shaft
⇒ page 165
7 - Tapered roller bearing outer
race
❑ For input shaft
⇒ page 143
❑ If replaced, adjust the output shaft ⇒ page 150
8 - Tapered roller bearing outer race
❑ For input shaft
❑ If replaced, adjust the output shaft ⇒ page 133
9 - Needle bearing
10 - Adjustment bush
❑ 2 off
11 - Clutch housing
❑ If replaced: ⇒ “2 Adjustment overview”, page 165
12 - Spherical head pin
❑ removing and fitting ⇒ Item 2 (page 32)
13 - Guide bushing
❑ With input shaft seal and vulcanised or bonded O-ring
❑ Knocking out oil seal ⇒ page 113
❑ Driving in oil seal ⇒ page 113
❑ Remove guide sleeve in order to renew oil seal
❑ If O-ring is damaged or has come loose, renew guide sleeve and O-ring together

14 - Cylindrical bolt
15 - Oil seal
❑ replace with gearbox installed ⇒ page 157
16 - Drift sleeve
❑ For seal ⇒ Item 15 (page 112) .
❑ Levering out ⇒ page 113
17 - Oil drain plug, 35 Nm
18 - Outer track, roller bearing
❑ For the differential
❑ If replaced: adjust the differential ⇒ page 174
19 -permitted
Magnet unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Supported by the application surface of the housing
❑ If replaced: adjust the differential ⇒ page 174
21 - Shim
❑ Adjustment overview ⇒ page 165
22 - Oil seal
Driving out needle roller bearing
Driving needle bearing in to stop

– Secure needle bearing in gearbox housing at three points
(120° offset) with a punch.

Driving oil seal out of guide sleeve
Driving oil seal into guide sleeve (drive in onto stop)
Levering out sleeve -arrow- using screwdriver
Pulling in sleeve
A - Screw spindle of assembly tool - 3066- into threaded piece of
differential.
B - M12 nut with washer
– Turn nut -B- and pull sleeve in onto stop with thrust piece -
3124- .
Note
With gearbox dismantled, press sleeve in to stop using thrust

piece - 3124- .

Pulling out sleeve and seal

A shoulder is located on inside diameter of sleeve.
– To pull out seal and sleeve, apply extractor hooks -
VW 771/37- behind shoulder in sleeve.
– When extracting, the extraction lever - VW 771/37- must be
pressed tight in the sleeve.
Pulling in sleeve and seal

– Clean seat for seal in gearbox.
differential.
B - Nut M12
– Turn nut -B- and pullbysleeve
Protected copyright.in ontoforstop
Copying privatewith thrust purposes,
or commercial piece -in part or in whole, is not
T10148- . permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Note
With gearbox dismantled, press sleeve in to stop using thrust

piece - T10148- .

7 Selector unit (gearbox side) disassembly and assembly (selector shaft

can be removed from the selector cover)

equipment required
♦ Pressure plate - VW 401-
♦ Press die - VW 408 A-
♦ Tube element - VW 423-
♦ Guide - VW 439-
♦ Thrust pad - VW 447 i-
♦ -1- Interior extractor - Kuk‐
ko 21/3-
♦ Plunger - T10203-
7. Selector unit (gearbox side) disassembly and assembly (selector shaft can be removed from the selector cover) 115
Note

1 - Selector shaft
❑ During a downshift from
5th to 4th gear, the bolt
guides the selector shaft
along the shoulder
-arrow- to 4th gear gate.
2 - Stop ring
3 - Ball sleeve
4 - Selector rod cover
❑ With angled rod for set‐
ting selector mecha‐
nism
❑ Removing angled rod
⇒ page 117
❑ Pressing in angled rod
⇒ page 117
5 - Bolt, 15 Nm
6 - Reversing light switch - F4- ,
20 Nm
❑ Lightly coat lug with
MoS2 grease
7 - Return lever
⇒ page 44
❑ After installation, the Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
gear change mecha‐ permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
nism must be adjusted respect to the correctness of information in this document. Copyright by SEAT S.A.
⇒ page 49
8 - Oil seal
❑ Remove levering with a screwdriver
9 - Cap
❑ For gearbox breather
10 - Hexagonal nut
11 - Gear lever
❑ Installing ⇒ Item 11 (page 43)
12 - End cover
13 - Spring
❑ If present, insert in cover.

Removing ball sleeve from selector mechanism cover

– Before pulling out ball sleeve, destroy plastic cage and remove
balls.
A - Internal puller , e. g. -Kukko 21/3- , 18.5 … 23.5 mm
Removing angled rod -A- from selector shaft cover

– Remove outer part of angled rod.
– Then carefully lever out angled rod using a screwdriver.
Pressing angled rod -A- into selector shaft cover

Installation position:
Marking -arrow- points to upper part of selector shaft.
Inserting oil seal to stop Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
7. Selector unit (gearbox side) disassembly and assembly (selector shaft can be removed from the selector cover) 117
Fitting the ball socket in the selector shaft cover
Inserting oil seal to stop

8 Selector unit (gearbox side) disas‐

sembly and assembly (selector shaft
cannot be removed from the selector
cover)
♦ Tube element - T10203-
Note

8. Selector unit (gearbox side) disassembly and assembly (selector shaft cannot be removed from the selector cover) 119
1 - Selector unit
❑ Consists of selector
shaft and selector shaft
cover
❑ Components cannot be
separated from each
other
2 - Reversing light switch - F4-
❑ Tighten to 20 Nm
❑ Lightly coat lug with
MoS2 grease
3 - Angled rod
❑ To adjust the gear se‐
lection mechanism
4 - Relay lever
⇒ page 44
⇒ page 45
❑ After installation, the
gear change mecha‐
nism must be adjusted
⇒ page 49
5 - Wiring clip unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted
❑ For relay lever with hole
in bearing shaft
6 - Seal for selector shaft
❑ Remove levering with a
screwdriver
7 - Hexagonal nut
8 - Gear lever
❑ Installing ⇒ Item 11 (page 43)
9 - Cover
❑ For gearbox breather
10 - End cover
11 - Spring
❑ If present, insert in cover.

9 Dismantling and assembling selector forks

equipment required
♦ Thrust piece - 3290/1- from
assembly tool - 3290-
♦ Assembly tool - 3301-
♦ Spacer sleeve - VW 472/2-
♦ Press tool - 10-206-
♦ Lever for releasing - 80-200-
9. Dismantling and assembling selector forks 121

♦ Drift - 10-508-
♦ attachment tool - 2070-
Note
It is not necessary to dismantle the selector fork cluster to remove and assemble the selector segments, the
fastening washers and the ball bearings ⇒ Item 7 (page 123) .

1 - 5th gear selector segment

❑ Identification
⇒ page 123
❑ Detent segment should
turn freely after lock
washer is installed.
2 - Securing washer
❑ Always replace
3 - 5th gear selector fork
4 - Bolt, 25 Nm
5 - 5th gear selector jaw
6 - Angular contact ball bearing
❑ 4 off
❑ Press inner race into
outer race ⇒ page 124
7 - Gearbox prong unit with
strips
8 - 1st/2nd gear selector seg‐
ment
❑ Identification
⇒ page 123
❑ Detent segment should
turn freely after lock
washer is installed.
9 - Selector segment for 3rd
and 4th gear
❑ Identification
⇒ page 123
❑ Detent segment should turn freely after lock washer is installed.
10 - Sliding piece
11 - Spring
12 - Selector fork for reverse gear
13 - Support for reverse gear selector fork
14 - Securing ring
Identification of the gear groups

Gap -a-
1 - Selector segment for 1st and 2nd gear = 11.4 mm
2 - Selector segment for 3rd andpermitted
4th respect
gear
unless=authorised
7.6 mm by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
3 - Selector segment for 5th gear = 6.0 mm

Removing lock washer

– Fasten the prong to a workshop vice with clamps -B-.
– Remove the washer -A- by levering in the direction of the ar‐
row.
Installing lock washer

– Press lock washer into groove of selector segment using sock‐
et and spinner handle.
Note
Detent segment should turn freely after lock washer is installed.
A - Spinner handle with 10 mm socket

B - Protective jaw covers
Remove ball bearings

Note
Do not bend the prongs when removing and fitting the ball bear‐
ings.
Pressing inner race -A- of angular contact ball bearing into outer
race
The inner ring should fit in the outer ring.

Fit the ball bearings as far as possible in the gearbox prong

Depression in thrust piece - 3290/1- faces ball bearing.
Selector fork with mounted selector segments

Value -a- (mm)
1st/2nd gear selector fork 88,4 … 89,1
prong of 3rd/4th gear 96,0 … 96,7
For identification of detent segments ⇒ page 123

35 – Gears, shafts
1 Input shaft:
⇒ “1.1 Disassembly and assembly of the input shaft”, page 126
⇒ “1.2 Input shaft: adjustment”, page 133
1.1 Disassembly and assembly of the input shaft

equipment required
♦ Press die - VW 407-
♦ Thrust pad - VW 447 H-
126 Rep. gr.35 - Gears, shafts


♦ Pressure disk - VW 447 i-
♦ Drift sleeve - 41-501-
♦ -3- Splitter - Kukko 17/1-
Note
♦ When installing new gears or a new input shaft, all details of the ⇒ Electronic parts catalogue “ETKA” and
technical data must be observed.
♦ If the position of the tapered roller bearings is affected when parts are exchanged, the input shaft must be
readjusted. Consult adjustment chart . ⇒ page 165
1. Input shaft: 127

1 - Clutch housing
❑ Pressing out
⇒ page 129
3 - Inner ring and roller bearing
unit
❑ Pressing out
⇒ page 130
4 - Drive shaft
5 - Gear wheel for 3rd gear
❑ The collar points to‐
wards the 4th gear
❑ Pressing out
⇒ page 130
❑ Driving inpermitted
⇒ page 131
6 - Securing ring
❑ Always replace
7 - Gear wheel for 4th gear
❑ Pressing off with ta‐
pered roller bearing out‐
er race and sleeve
⇒ page 130
❑ Collar faces 3rd gear
8 - Inner ring and roller bearing
unit
❑ Pressing off with 4th
gear wheel and sleeve
⇒ page 130 .
9 - Thrust washer
❑ Pressing out ⇒ page 132
11 - Shim
❑ Determining thickness ⇒ “1.2 Input shaft: adjustment”, page 133
12 - Gearbox housing
13 - Drift sleeve
❑ For needle bearing
❑ Press off with gear wheel for 4th gear and tapered roller bearing inner race ⇒ page 130
❑ Set thrust washer ( ⇒ Item 9 (page 128) ) in place before installing
14 - Needle bearing
15 - Mobile pinion of 5th gear
❑ Pull off together with 5th gear synchronising hub ⇒ page 94
16 - Synchromesh ring of 5th gear:
❑ With cast locking pieces ⇒ page 107

❑ Check for wear ⇒ page 106

17 - Spring
❑ Installing springs with bent ends ⇒ page 133
18 - Locking pieces (3 off)
19 - Synchro-hub for 5th gear
❑ Dismantling and assembling ⇒ page 132
20 - Locking collar for 5th gear
21 - Dished washer
22 - Bolt ⇒ Item 4 (page 85)
❑ Always replace
❑ Fitted section of bolt head holds dished spring in position ⇒ page 108
Pressing out tapered roller bearing outer race
Pressing in tapered roller bearing outer race
1. Input shaft: 129

Pressing off tapered roller bearing inner race

A - Separator - Kukko 17/1-
Pressing on tapered roller bearing inner race
Pressing off gear wheel for 4th gear with tapered roller bearing
and sleeve
Pressing off 3rd gear wheel

Pressing on gear wheel for 3rd gear
Pressing on 4th gear wheel

Shoulder faces 3rd gear
Pressing on tapered roller bearing inner race
Pressing
respect toon
the sleeve
correctnessfor needle inbearing
of information this document. Copyright by SEAT S.A.
1. Input shaft: 131

Pressing out tapered roller bearing outer race
Pressing in tapered roller bearing outer race

– Install with shim after adjusting input shaft.
5th gear synchromesh

1- Springs for locking pieces
2- Locking collar with 3 recesses -arrows A- for the locking
pieces -item 4-
3- Synchro-hub
4- Locking keyways. Installation position: the recess
-arrow B- points to the teeth terminating in the end of the
sliding sleeve -2-.
Assembling 5th gear locking collar/synchro-hub

– Slide locking collar over synchro-hub.
Pointed teeth -A- and shoulder -B- of synchro-hub face in same
direction. The recesses for the locking pieces in locking collar and
synchro-hub must be aligned ( ⇒ page 132 ).
– Insert locking pieces (Installation position: ⇒ page 132
– Install springs offset by 120°, below shoulder -C-. Springs
must seat with angled ends in front of locking pieces.
-arrows-.

Installing springs with bent ends -A-

These springs are installed on both sides.
– Spring are installed only in conjunction with hollow locking
pieces.
– Insert locking pieces (Installation position: ⇒ page 132
Installation location of the corrugated spring washers:

– Insert the washers offset by 120°.
– Angled end of spring washer -A- must locate in hollow locking
piece.
The spring washer must be fitted under the protrusion -B- of lock‐
ing pieces.
Bent ends always face away S.Afrom synchro-hub
permitted unless authorised by SEAT S.A. SEAT does not guarantee or accept any liability with
1.2 Input shaft: adjustment

(Determining thickness of shim for input shaft)
1. Input shaft: 133


equipment required
♦ Universal bracket for gauge
- VW 387-
♦ Final measurement plate -
VW 385/17-
♦ Thrust pad - VW 447 i-
V.A.G 1331-
♦ Dial gauge
The input shaft must be re-adjusted when the following compo‐

nents are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Drive shaft
♦ Gear wheel for 4th gear
♦ Tapered roller bearing
Adjustment overview ⇒ page 165
Prerequisite:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant.

– Press tapered roller bearing outer race without shim into gear‐
box housing to stop.
– Press tapered roller bearing outer race without shim into gear‐
box housing to stop.
– Install input shaft in clutch housing and set gearbox housing
in place. Tighten hexagon bolts to 25 Nm, then turn 90° further.
– Fit measuring appliance and dial gauge inunless
permitted clutch housing
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
(large tapered roller bearing in gearbox respect
housing).
– Before taking any measurements, rotate input shaft to allow

bearings to settle. Set dial gauge to “0” with 1 mm preload.
Note
This step must be repeated for each subsequent measurement,

or the dial gauge will not return to the starting position.
– Press input shaft in direction of dial gauge

– Read the play measured on the gauge and take note (exam‐
ple:
Note
Dial gauge does not return to original position.
– Determine thickness of shim from table ⇒ page 136 (Example:

– Remove input shaft and press tapered roller bearing outer
race out of gearbox housing using -VW 447 i- .
– Press tapered roller bearing outer race together with the
1.175 mm shim into gearbox housing using -VW 510- .
– Assemble gearbox housing and tighten hexagon bolts to 25
Nm and then turn 90° further.
1. Input shaft: 135

1.2.1 Determining thickness of shim

Example:
Bearing play, measured value Thickness of shim according to
table
1.21 mm 1.175 mm
Shim table
Bearing play Shim
Measured value (mm) Thickness (mm)
0,671…0,699 0,650
0,700…0,724 0,675
0,725…0,749 0,700
0,750…0,774 0,725
0,775…0,799 0,750
0,800…0,824 0,775
0,825…0,849 0,800
0,850…0,874 0,825
0,875…0,899 0,850
0,900…0,924 0,875
0,925…0,949 0,900
0,950…0,974 0,925
0,975…0,999 0,950
1,000…1,024 0,975
1,025…1,049 1,000
1,050…1,074 1,025
1,075…1,099 1,050
1,100…1,124 1,075
1,125…1,149 1,100
1,150…1,174 1,125
1,175…1,199 1,150
1,200…1,224 1,175
1,225…1,249 1,200
1,250…1,274, 1,225
1,275…1,229 1,250
1,300…1,324 1,275
1,325…1,349 1,300
1,350…1,374 1,325
1,375…1,399 1,350
1,400…1,424 1,375
1,425…1,449
Protected by copyright. Copying for private 1,400
or commercial purposes, in part or in whole, is not
1,450…1,474 1,425
1,475…1,499 1,450
1,500…1,524 1,475
1,525…1,549 1,500
1,550…1,574 1,525
1,575…1,599 1,550
1,600…1,624 1,575
1,625…1,649 1,600
1,650…1,674 1,625
1,675…1,699 1,650
1,700…1,724 1,675
Note
Allocate shims according to ⇒ Electronic parts catalogue “ETKA” .

– Remove input shaft and press outer race of tapered roller

bearing out of gearbox housing using thrust plate - VW 447 i- .
– Install shims of the calculated thickness, thickest shim first.
If the size of the shim required is larger than those listed in the
table, install two shims amounting to the correct value.
– Press outer race of tapered roller bearing together with the
shim (1.175 mm in example) into gearbox housing using thrust
pad - VW 510- .
– Set gearbox housing in place and tighten hexagon head bolts
to 25 Nm and then turn 90° further.
1.2.2 Carrying out check measurement

– Set up measuring appliance and dial gauge.
– Rotate input shaft to allow tapered roller bearings to settle.
– Press input shaft in -direction of arrow-.
– Bearing clearance should be min. 0.01 ... max. 0.09 mm.
Note
If the bearing play cannot be measured, but input shaft play is

perceptible and the input shaft turns freely, the adjustment is ac‐
ceptable.
1. Input shaft: 137

2 Output shaft
⇒ “2.1 Input shaft: disassembly and assembly”, page 138
⇒ “2.2 Secondary shaft: adjustment”, page 150
2.1 Input shaft: disassembly and assembly

equipment required
♦ Puller - V.A.G 1582-
♦ Locking device -
V.A.G 1582/4-
♦ Locking device -
V.A.G 1582/5-


♦ Insertion tool - 32-111-
♦ Mounting rails - VW 457-
2. Output shaft 139

♦ Installing ring - VW 429-

♦ Tube element - VW 415 A-
♦ Assembly sleeve - VW 455-
♦ Drift sleeve - 41-501-
♦ -1- Interior extractor - Kukko 21/6-
♦ -4- Support bracket - Kukko 22/2-

Note
♦ The output shaft is dismantled as follows: place splitter under 2nd speed selector gear
⇒ Item 21 (page 142) and press off as described in ⇒ page 144 Remove retaining ring
⇒ Item 17 (page 142) . Then press off locking collar with synchro-hub for 1st and 2nd gear as described in
⇒ page 145 .
♦ When installing new gears or a secondary input shaft, all details of the ⇒ Electronic parts catalogue “ETKA”
and technical data must be observed.
♦ Replace both conical roller bearings together.
1 - Hexagon nut, 25 Nm and

turn 90° further
❑ 4 nuts for bearing sup‐
port
❑ Always replace
2 - clutch housing
3 - Shim
⇒ page 165
4 - Small tapered roller bearing
outer race
❑ Remove ⇒ page 143
5 - Tapered roller bearing inner
race small
❑ Pressing out
⇒ page 144
6 - Output shaft
❑ A matched pair with the
wheel drive; they must
be replaced together
7 - Tapered roller bearing inner
race large
❑ Pressing out
⇒ page 145
8 - Oil
permitted seal
❑ Place seals (4x) on bolts
for bearing mounting

9 - Bearing support
❑ With large tapered roller bearing outer race and bolts
❑ Only renew outer race together with large tapered roller bearing and bearing mounting
10 - Thrust washer
❑ Shoulder of thrust washer faces tapered roller bearing
11 - Synchromeshed gear for 1st gear
❑ For 1st gear
2. Output shaft 141

13 - Synchro-ring
❑ (Inner ring for 1st gear)
❑ Check lugs for scoring
14 - Outer ring for 1st gear
❑ Replace if there are signs of scoring and wear
15 - Synchro-ring for 1st gear
16 - Locking collar with synchronising hub for 1st and 2nd gear
❑ After removing retaining ring ⇒ Item 17 (page 142) , pull off together with bearing support ⇒ page 145
❑ Dismantling ⇒ page 146
❑ Assembling locking collar and synchro-hub ⇒ page 146 , ⇒ page 147 and ⇒ page 147
17 - Securing ring
18 - 2nd gear synchroniser ring
❑ Fit so that the grooves insert in the locking elements of the mobile sleeve ⇒ Item 16 (page 142)
19 - Outer ring for 2nd gear
❑ Insert in synchro-ring ⇒ Item 18 (page 142) . Installation position ⇒ page 148 .
❑ Replace if there are signs of scoring and wear
20 - Synchro-ring
❑ (Inner ring for 2nd gear)
❑ Check lugs for scoring
21 - Synchromeshed gear for 2nd gear
❑ Of 2nd gear
23 - Thrust washer
24 - Sleeve for 3rd gear needle bearing
❑ Pressing off with synchromeshed gear for 2nd gear ⇒ page 144
❑ Insertion
Protected⇒
by page 148
25 - Gear needle
respectroller bearingof information in this document. Copyright by SEAT S.A.
to the correctness
❑ for 3rd gear

26 - 3rd speed selector gear
27 - Synchromesh ring of 3rd gear
28 - Locking collar with synchro-hub for 3rd and 4th gears
❑ Press off with 2nd gear synchromeshed gear ⇒ Item 21 (page 142) and 3rd gear ⇒ Item 26 (page 142)
⇒ page 144 .
❑ Dismantling ⇒ page 149

❑ Assembling locking collar and synchro-hub ⇒ page 149 , ⇒ page 149 and ⇒ page 149
❑ Installation position of the mobile element/synchromesh body. ⇒ page 150
29 - Drift sleeve
❑ For needle bearing
❑ Press off with 3rd and 4th gear ⇒ Item 28 (page 142) locking collar and synchro-hub ⇒ page 144 .
❑ For 4th gear
31 - Synchro-ring for 4th gear
32 - 4th speed selector gear
33 - Thrust washer
35 - Gearbox housing
36 - Drift sleeve
❑ For output shaft needle bearing
37 - 5th gear pinion
38 - Dished washer
39 - Bolt ⇒ Item 4 (page 85)
❑ Always replace
❑ Fitted section of bolt head holds dished spring in position ⇒ page 108
Pulling out small tapered roller bearing outer race

A - Internal puller 37...46 mm , e.g. -Kukko 21/6-
B - Counter-support , e.g. -Kukko 22/2-
2. Output shaft 143

Pressing in small tapered roller bearing outer race
Pulling off small tapered roller bearing inner race

A - Vice with protective jaw covers
– Fit adapter and tighten behind bearing rollers, then turn bear‐
ing and retighten gripping device.
Pressing on small tapered roller bearing inner race

Pressing off 3rd and 4th gear synchro-hub and locking collar, 2nd,
3rd and 4th gear synchromeshed gears with sleeve for gearbox
housing needle bearing
A - Splitter 22...115 mm , e.g. -Kukko 17/2-
B - Hexagon bolt M10 x 20, 17 mm AF
Note
Support splitter so that the 1st and 2nd gear locking collar is not
pulled off at the same time.

Pressing off locking collar with synchro-hub and bearing support

– First remove retaining ring -arrow-.
Pulling off large tapered roller bearing inner race

A - Protective jaw covers
– Before fitting puller, insert a M 10 x 20 hexagon bolt in the
output shaft drilling.
Pressing on large tapered roller bearing inner race

A - Thrust washer
– Fit thrust washer before pressing on inner race. Shoulder
faces towards inner race.
Installation position of outer ring for 1st gear

– Fit the interior ring -A- onto the mobile pinion for 1st gear.
The tabs -arrow 1- must point to the outer ring -B-.
– permitted
Fit theunless
outer
Protected ringCopying
by copyright. -B-. for private or commercial purposes, in part or in whole, is not
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed
gear.
– Fit the synchroniser ring -C-.
Notches -arrow 4- engage in lugs -arrow 1- of inner ring -A-.
Note
If components are not to be renewed, ensure that they are match‐

ed with their original gears.
2. Output shaft 145

Checking inner ring for 1st and 2nd gear for wear
– Press inner ring onto tapered seat on selector gear and meas‐
ure gap -a- using a feeler gauge.
Gap -a-. Installation dimen‐ Wear limit
sion
1. and 2nd gear 0.75 … 1.25 mm 0.3 mm
Checking 1st and 2nd gear synchro-ring for wear

– Press synchro-ring, outer ring and inner ring against tapered
seat on selector gear and measure gap -a- using a feeler
gauge.
sion
1. and 2nd gear 1.2 … 1.8 mm 0.5 mm
Disassembly and assembly of the mobile element / synchroniser

body unit for 1st and 2nd gear
1 - Spring
Allocate spring using ⇒ Electronic parts catalogue (ETKA) .
Installation with hollow locking pieces ⇒ page 147 .
Installation with solid locking pieces ⇒ page 147 .
1- Mobile element
2- Synchro-hub
3- Locking piece
Allocate locking pieces using ⇒ Electronic parts catalogue (ET‐
KA) .
Collar is equally wide on both sides of synchro-hub.
Collar has chamfer on one side -arrow B-.
Chamfer on collar of synchro-hub and outer teeth of locking collar
-arrow A- face in same direction after assembly.
Notches -arrow C- in synchro-hub and sliding collar for locking
pieces must align.

Assembly of 1st and 2nd gear locking collar and synchro-hub with
hollow locking pieces
• The mobile element is on the synchromesh body.
– Insert the locking elements and install flexible rings offset by
120º. Angled end of spring washer must locate in hollow lock‐
ing piece.
Assembly of 1st and 2nd gear locking collar and synchro-hub with
solid locking pieces
120º. Springs must seat with angled ends in front of locking
pieces -arrows-.
Installation position of locking collar with synchro-hub for 1st and

2nd gears
Teeth of locking collar -arrow- face splines for 3rd and 4th gear
synchro-hub -A-.
Pressing on locking collar and synchro-hub for 1st and 2nd gears
Turn synchro-ring so that grooves align with locking pieces.
2. Output shaft 147

Installation position of 2nd gear outer ring

The lugs -arrows- face towards 1st gear -A-.
Installation position of synchro-ring (2nd gear inner ring) -A-

Lugs -arrow 1- engage in notches -arrow 2- in synchro-ring -B-.
Installation of 2nd gear mesh

The higher shoulder -A- faces towards 1st gear -B-. Notches in
shoulder -arrows- engage in lugs of outer ring (-arrow-
⇒ page 148 ). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Pressing on sleeve for 3rd gear needle bearing

Checking synchro-rings for 3rd and 4th gear for wear

– Press the synchromesh ring against the mobile pinion cone
and measure the distance -a- with a thickness gauge.
sion
1st gear 1.0 ... 1.7 mm 0.5 mm
3rd gear 1.0 ... 1.7 mm
4th gear 1.0 ... 1.7 mm
Dismantling and assembling 3rd and 4th gear locking collar and
synchro-hub
1 - Spring
Allocate spring using ⇒ Electronic parts catalogue (ETKA) .
Installation with hollow locking pieces ⇒ page 149 .
Installation with solid locking pieces ⇒ page 149 .
2 - Locking piece
Allocate locking pieces using ⇒ Electronic parts catalogue (ET‐
KA) .
3 - Mobile element
4 - Synchro-hub
– The mobile element is fitted onto the synchroniser body.
The recesses of the synchromesh assembly and mobile element
must lie over another for the locking elements.
Assembly of 3rd and 4th gear locking collar and synchro-hub with
hollow locking pieces
The mobile element is on the synchromesh body.
120º. Angled end of spring washer must locate in hollow lock‐
ing piece.
Assembly of 3rd and 4th gear locking collar and synchro-hub with
solid locking pieces
120º. Springs must seat with angled ends in front of locking
pieces -arrows-.
2. Output shaft 149

Installation position of locking collar with synchro-hub for 3rd and

4th gears
Chamfer -arrow- faces 4th gear.
Pressing on synchro-hub with locking collar for 3rd and 4th gears
Pressing on sleeve for 4th gear needle bearing
Pressing on sleeve for needle bearing/output shaft
2.2 Secondary shaft: adjustment

(Determining thickness of output shaft shim)


equipment required
- VW 387-
VW 385/17-
♦ Straightening tool - 3114/2-
V.A.G 1331-
♦ Dial gauge

The output shaft must be re-adjusted when the following compo‐
nents are renewed:
♦ Output shaft
♦ Clutch housing
♦ Tapered roller bearing
Adjustment overview ⇒ page 165
2. Output shaft 151

Prerequisite:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant.
– Press outer ring of small tapered roller bearing to stop with
0.65 mm shim into clutch housing ⇒ page 144 .
– Insert output shaft and tighten bearing mounting nuts to 25 Nm
and then turn 90° further.
– Turn output shaft 20 to 30 times in one direction.
Note
♦ The shaft must be turned in one direction so that the rollers of

the tapered roller bearing settle in one direction.
♦ It is necessary to turn the shaft 20 to 30 times to achieve this.
♦ Otherwise the resulting reading will be incorrect.
– Mount dial gauge (3 mm measuring range) and set to “0” with

1 mm preload.
– Move output shaft up and down. Read and note play indicated
on dial gauge.

The specified bearing preload will be attained if the determined
measured value is added to the 0.65 mm shim already installed.
Example:
Bearing play = Thickness of shim according to
(0.65 mm shim table
plus determined measured val‐
ue)
0.740 mm 0.900 mm
Shim table
Bearing play = Shim
(0.65 mm shim thickness (mm)
ue)
0,650Copying for private or commercial purposes,
Protected by copyright. 0,750
in part or in whole, is not
0,660
permitted unless … 0,689
authorised 0,800
by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
0,690 … 0,739 0,850
0,740 … 0,789 0,900
0,790 … 0,839 0,950
0,840 … 0,889 1,000
0,890 … 0,939 1,050
0,940 … 0,989 1,100
0,990 … 1,039 1,150
1,040 … 1,089 1,200
1,090 … 1,139 1,250

Bearing play = Shim

(0.65 mm shim thickness (mm)
ue)
1,140 … 1,189 1,300
1,190 … 1,239 1,350
1,240 … 1,289 1,400
1,290 … 1,339 1,450
1,340 … 1,389 1,500
1,390 … 1.429 1,550
Note
– Remove output shaft and pull out small tapered roller bearing
outer race ⇒ page 143 .
• If the previously used 0.65 mm shim is to be reinstalled, check
it for damage.
If the required thickness for the shim is more than that indicated
on the table, two shims may be fitted together in order to reach
the determined thickness.
– Press in outer race of small tapered roller bearing together with
the calculated shim ⇒ page 144 and install output shaft. Tight‐
en bearing support nuts in clutch housing to 25 Nm and then
turn 90° further.
2. Output shaft 153

3 Reverse gear shaft:

⇒ “3.1 Dismantling and assembling reverse shaft”, page 154
3.1 Dismantling and assembling reverse shaft

equipment required
♦ Centring mandrel. - 12-551-

Note
After removal, always renew needle bearings in clutch housing and in reverse shaft support.
1 - clutch housing
2 - Needle bearing
❑ Remove ⇒ page 155
3 - Reverse gear pinion
4 - Securing ring
❑ Always renew after re‐
moving.
5 - Reverse gear synchro‐
meshed gear
❑ The locking ring has to
be removed before in‐
stalling
❑ Shoulder faces reverse
gear wheel
6 - Reverse gear shaft:
7 - Needle bearing
❑ Pressing out
⇒ page 156
8 - Reverse shaft support
❑ removing and fitting
⇒ page 94
Pulling needle bearing out of clutch housing

A - Internal puller , e.g. -Kukko 21/2-
B - Counter-support , e.g. -Kukko
Protected by copyright. Copying for private or22/1-
commercial purposes, in part or in whole, is not
Note
The needle bearing is destroyed during removal and must be re‐

newed.
3. Reverse gear shaft: 155

Pressing needle bearing -A- into clutch housing
Pressing needle bearing out of reverse shaft support
Pressing needle bearing into reverse shaft support

39 – Final drive - differential

1 Replace seals for flanged shafts with
installed equipment
⇒ “1.1 Renewing oil seal for left flange shaft”, page 157
⇒ “1.2 Distinguishing seals for right flange shaft”, page 159
⇒ “1.3 Renewing seal (two-part seal and sleeve for right flange
shaft)”, page 159
⇒ “1.4 Renewing seal and sleeve together (one-piece seal and
sleeve for right flange shaft)”, page 162
1.1 Renewing oil seal for left flange shaft


equipment required
♦ Extraction hook -
VW 771/37-
♦ Tray - V.A.G 1306-
hoist - VAS 6208-
♦ Torque wrench -
V.A.G 1331-
1.1.1 Detaching
– Remove left wheel.
1. Replace seals for flanged shafts with installed equipment 157

– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 .
– Turn steering to the left.
– Unbolt drive shaft from flange shaft.
– If fitted, remove coupling rod -1- from anti-roll bar ⇒ Running
– Unscrew the nuts -arrows- that fix the ball joint to the
permitted rocker
arm ⇒ Running gear, axles, steering; Rep. gr. 40respect. to the correctness of information in this document. Copyright by SEAT S.A.
– Swing wheel bearing housing outwards.

– Remove the left bearing by guiding it out between the sub‐
frame assembly and the gearbox.
– When doing this, guide drive shaft into wheel housing and se‐
cure to suspension strut with wire. Take care not to damage
paint on drive shaft in the process.
– Place drip tray under the gearbox.
– Extract the bolt fastening the flanged shaft. To do so, thread

2 bolts on the flange and lock the shaft using the assembly
lever.
– Remove flanged shaft together with compression spring.
– Pull out flange shaft oil seal using -VW 771- and -VW 771/37- .
158 Rep. gr.39 - Final drive - differential

1.1.2 Installing
– Fit a new seal as far as possible without tilting.
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease - G 052 128 A1- .
– Fit flanged shaft.
– Secure flange shaft with countersunk bolt
– Fit the drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 .
– Unscrew the ball joint to the rocker arm ⇒ Running gear, axles,
– Secure the coupling rod to anti-roll bar ⇒ Running gear, axles,
– Mount the wheel ⇒ Running gear, axles, steering; Rep. gr.
44 .
– Check gear oil level and top up to lower edge of oil filler hole
if necessary ⇒ page 81 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50
1.2 Distinguishing seals for right flange

shaft
The seal -1- for the right flange shaft is located in a sleeve -2-.
There are different versions.
Seal -1- and sleeve -2- are two parts. notches arranged along he
length of sleeve -arrow-.
Renew seal ⇒ page 159 .
Seal -1- and sleeve -2- are one piece. Identification characteristic:
there are no recesses on the sleeve.
Renew
permitted unless seal and
authorised by sleeve
SEAT S.A. together
SEAT S.A does ⇒not
page 162or.accept any liability with
guarantee
1.3 Renewing seal (two-part seal and

sleeve for right flange shaft)

♦ Tray - V.A.G 1306-
♦ or drip tray for workshop hoist - VAS 6208-

1.3.1 Detaching
Rep. gr. 50 .

– Turn steering to full right lock.

– Hang up the drive shaft as high as possible. Take care not to
damage paint on drive shaft in the process.
– If necessary, unscrew the oil return pipe from the exhaust gas
turbocharger ⇒ Rep. gr. 21 .

two bolts on the flange and lock the shaft using the assembly
lever.
– Lever out oil seal using a screwdriver -A- (support screwdriver

on assembly tool - 3253/2- ).
Note
♦ Do not damage sleeve. Otherwise, leaks will occur.

♦ Renew sleeve if damaged ⇒ page 113
1.3.2 Installing
– Fit a new seal as far as possible without tilting.
ing grease - G 052 128 A1- .
– If previously unscrewed, screw the turbocharger oil return line
back onto the engine ⇒ Rep. gr. 21 .
– Screw the driveshaft to the flanged shaft ⇒ Running gear,
shafts, steering; Rep. gr. 40 .


gr. 50
1.4 Renewing seal and sleeve together

(one-piece seal and sleeve for right
flange shaft)


♦ Spindle from assembly tool - 3066-
♦ Extraction hook - VW 771/37-
♦ Tray - V.A.G 1306-
♦ or drip tray for workshop hoist - VAS 6208-
1.4.1 Detaching
Rep. gr. 50 .
– Turn steering to full right lock.
– Hang up the drive shaft as high as possible. Take care not to
damage paint on drive shaft in the process.
– If necessary, unscrew the oil return pipe from the exhaust gas
turbocharger ⇒ Rep. gr. 21 .

two bolts on the flange and lock the shaft using the assembly
lever.

– Pull out seal and sleeve together.

A projection is located on inside diameter of sleeve.
– Apply puller hooks - VW 771/37- directly behind shoulder in
sleeve.
– When extracting, the extraction lever - VW 771/37- must be
pressed tight in the sleeve.
1.4.2 Installing
– Clean seat for seal in gearbox.
– Pull in seal and sleeve together.
differential.
B - Nut M12
– Pull in seal with sleevepermitted
to stop using
unless thrust
authorised piece
by SEAT S.A.- SEAT
T10148-
S.A doesby
not guarantee or accept any liability with
turning nut -B-. respect to the correctness of information in this document. Copyright by SEAT S.A.
ing grease - G 052 128 A1- .
– If previously unscrewed, screw the turbocharger oil return line
back onto the engine ⇒ Rep. gr. 21 .
– Screw the driveshaft to the flanged shaft ⇒ Running gear,
shafts, steering; Rep. gr. 40 .

gr. 50

2 Adjustment overview
Note
If repairs have been carried out to the gearbox, it is necessary to

adjust the input shaft, output shaft or differential only if compo‐
nents have been renewed which have a direct effect on the
adjustment of the gearbox. The following table must be consulted
to avoid unnecessary adjustment work:
Adjustment must be made to the

Input shaft Output shaft Differential
⇒ page 133 ⇒ page 150 ⇒ page 174
Components renewed: Gearbox housing x x
Clutch housing x x x
Drive shaft x
Output shaft x
Differential cage x
Conical roller bearing for input shaft x
Conical roller bearing of the output x
shaft
Differential roller bearings x
Gear wheel for 4th gear x
2. Adjustment overview 165

3 Differential assembly
⇒ “3.1 Differential: assembly and disassembly”, page 166
⇒ “3.2 Differential: Adjust”, page 174
3.1 Differential: assembly and disassembly

equipment required
♦ Roller bearing bush extrac‐
tor - V.A.G 1582-
♦ Locking device - V.A.G
1582/3-


♦ Pressure plate - 30 - 205-
♦ Sleeve - 3144-
♦ Thrust pad - 2007-
1332-
♦ Pressure plate - 40-105-
3. Differential assembly 167

♦ Internal puller - 1-Kukko 21/7-
♦ Counter-support - 4-Kukko 22/2-
Note
♦ Heat tapered roller bearing inner race to 100° C before installing.

♦ Replace both conical roller bearings together.
♦ If tapered roller bearings, differential cage, gearbox housing or clutch housing is renewed, adjust differential
⇒ page 174 .
1 - Gearbox
2 - Plug
3 - Differential cage
❑ Bolt to final drive gear
❑ Hole for spring pin adap‐
ted to length of spring
pin ⇒ page 173
❑ Corresponding to ⇒
Electronic catalogue of
spare parts“ETKA”
❑
4 - Differential crown:
❑ Riveted in the factory
❑ Pressing out
⇒ page 172
❑ Installation position Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 172 permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Heat to 100° C before
installing.
❑ Fit to differential cage
⇒ page 172
❑ Bolted ⇒ page 172
5 - Plate supplement
6 - Nut, 70 Nm
7 - Shim
❑ Determining thickness
⇒ page 174
❑ Pressing out

⇒ page 171
9 - Inner ring and roller bearing unit
10 - Differential cage
❑ With the wheel drive shaft riveted gear
❑ Drill out rivet heads when renewing final drive gear ⇒ page 171
❑ Attaching final drive gear with bolts ⇒ page 172
11 - Speedometer drive sprocket
❑ If present, fit into differential cage to stop before pressing on inner race
12 - Inner ring and roller bearing unit
14 - Clutch housing
15 - Drift sleeve
❑ For seating oil seal ⇒ Item 16 (page 169)
16 - Oil seal
17 - One-piece seal and sleeve
❑ If seal is damaged, renew seal and sleeve together ⇒ page 157
❑ Screw into threaded piece ⇒ Item 26 (page 169)
19 - Flange shaft Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted ⇒ page
unless authorised by 157
SEAT S.A. SEAT S.A does not guarantee or accept any liability with
20 - Compression spring for flange shaft
❑ Installed behind flange shafts
21 - Thrust washer
❑ Installation position: with collar towards the spring, the protrusions towards conical ring
❑ Installation position with modified thrust washer ⇒ page 174
22 - Tapered ring
❑ With slots for the thrust washer
❑ Installation position: conical side facing the differential casing
23 - Securing ring
❑ Keep the following in position: conical ring, shim and pressure spring for flanged shaft when it is dis‐
mantled
24 - Set of thrust washers
❑ Lubricate with gear oil before installing
25 - Large planet gear
26 - Threaded piece

27 - Differential pinion pin

❑ Removing in conjunction with shorter spring pin ⇒ page 173
❑ Removing in conjunction with longer spring pin ⇒ page 173
28 - Spring pin
❑ For securing differential pinion pin
❑ Spring pins of different lengths have been installed
❑ Spring pin identification ⇒ page 173
❑ Removing and installing short spring pin ⇒ page 173
❑ Long spring pin: shearing off for removal ⇒ page 173
❑ Installing long spring pin ⇒ page 174
29 - Small planet gear
30 - Large planet gear
Pressing tapered roller bearing outer race out of clutch housing

– First remove seating sleeve for flange shaft seal.
Pressing tapered roller bearing outer race into clutch housing

No shim is installed in the clutch housing end.
Pulling off tapered roller bearing inner races

– Before setting up pulling device, set thrust plate - 40-105- on
differential housing.
Note
Both tapered roller bearing inner races are pulled off the differ‐
ential cage in the same way.

Fit inner ring and roller bearing units
Note
Both tapered roller bearing inner races are pressed onto the dif‐
ferential cage in the same way.
Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
A - Counter-support , e.g. -Kukko 22/2-
B - Internal puller 46 … 58 mm , e.g. -Kukko 21/7-
Fitting the outer ring of the roller bearing into the gearbox casing
– Fit shim under outer race.
– Support gearbox housing directly below bearing mounting us‐
ing sleeve - 3144- .
Drilling out rivet heads

– Drill out rivet heads with 12 mm drill bit from countersunk side
and drive rivets out with drift.
Note
Clean differential before and after drilling, protecting tapered roller

bearing from drillings.

Pressing off final drive gear

– Place thrust plate - 40-105- on differential cage.
Installation position of final drive gear

The circular groove -A- faces bolt-on surface of differential hous‐
ing.
Heating final drive gear wheel to approx. 100 °C and installing

– Use bolts -A- from repair kit to guide final drive gear into po‐
sition during installation.
Bolting final drive gear and differential cage together

Use special bolts with backing plates and nuts according to ⇒
Electronic parts catalogue (ETKA) .

Spring pin identification

Dim. “a” mm Distinguishing feature
28.5 (short spring pin), Circumferential groove
removing and installing ⇒ page 173 -arrows-
36.0 (long spring pin), No circumferential
Removing ⇒ page 173 , groove
Installing ⇒ page 174
Allocation of differential cages

– Check hole for spring pin in differential cage.
The hole in the differential cage was modified for the longer spring
pin.
Bore Length of spring pin (mm)
-A- 28.5 (short spring pin)
-A- and -B- 36.0 (long spring pin)
Removing and installing spring pin with circumferential groove

(short spring pin)
Detaching
– Cover tapered roller bearing inner race and speedometer drive
gear to avoid possible damage and ingress of metal particles.
– Remove the tension sleeve using a chisel, apply pressure to
the groove for this purpose.
Installing
– Fit to the differential casing as far as it will go.
Spring pin without annular groove (long spring pin): Removing

differential pinion pin
When pressed out, spring pin will be sheared off.
– Drive remainder of spring pin out of differential cage.

Installing spring pin without circumferential groove (long spring

pin)
– Align hole in differential pinion pin with hole in differential cage.
– Drive in new spring pin with drift -1- until dimension -a- =
3.0 mm is attained.
• The spring pin must not come in contact with gears with dif‐
ferential cage installed.
Installing differential bevel gears and differential pinion pin

– Lubricate one piece thrust washer with gear oil and install.
– Fit the two sun gears and secure them (for example using the
flanged shaft).
– Insert planet pinions offset 180° and pivot into position.
– Press the planetary gear shaft -arrow A- to the first small plan‐
etary gear.
– Place threaded pieces - arrows B - in the sun gears.
Installation position: rebate faces differential box gear train.
– Drive differential pinion pin into final position and secure with
spring pin.
Modified thrust washer for tapered ring -1-

Installation position:
If there are no lugs -A-, collar -arrow- faces spring -B-.
3.2 Differential: Adjust


equipment required
- VW 387-
VW 385/17-
♦ Pressure plate - 30-205-
V.A.G 1331-
♦ -1- Interior extractor - Kuk‐
ko 21/7-
♦ -4- Support bracket - Kukkopermitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
22/2- respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ -Messuhr-
The differential must be adjusted again when any one of the fol‐
lowing elements are changed:
♦ Gearbox
♦ Clutch housing
♦ Differential casing or
♦ Differential roller bearings
Adjustment overview ⇒ page 165 .
– Press tapered roller bearing outer race into clutch housing us‐
ing thrust plate - 30-205- ⇒ page 170 .
Note
Inner and outer tapered roller bearing races are paired. Do not
mix them up.
– Press outer race of tapered roller bearing without shim into

gearbox housing using thrust piece - 30-205- ⇒ page 171
– Place the differential on the clutch housing.
– Set gearbox housing in place and tighten 5 bolts to 25 Nm.

– Attach dial gauge and set to “0” with 1 mm preload.

– Move the differential up and down while reading the meas‐
urement on the gauge and noting the results (for example:
0.70 mm).

Example:
Bearing play, measured value Thickness of shim according to
table
0.70 mm 0.95 mm
Shim table
Bearing play Shim
Measured value Thickness
(mm) (mm)
0,303 … 0,449 0,650
0,450 … 0,499 0,700
0,500 … 0,549 0,750
0,550
Protected … 0,599
by copyright. 0,800
Copying for private or commercial purposes, in part or in whole, is not
permitted0,600 … 0,649
unless authorised 0,850or accept any liability with
by SEAT S.A. SEAT S.A does not guarantee
0,650
respect …correctness
to the 0,699 of information in this document.0,900Copyright by SEAT S.A.
0,700 … 0,749 0,950

0,750 … 0,799 1,000
0,800 … 0,849 1,050
0,850 … 0,899 1,100
0,900 … 0,949 1,150
0,950 … 0,999 1,200
1,000 … 1,049 1,250
1,050 … 1,099 1,300
1,100 … 1,149 1,350
1,150 … 1,199 1,400
Note

– Remove the gearbox casing and pull the outer ring / conical
roller bearing out of the gearbox housing.
Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
A - Counter-support , e.g. -Kukko 22/2-
B - Internal puller 46...58 mm , e.g. -Kukko 21/7-
If the required thickness for the shim is more than that indicated
on the table, two shims may be fitted together in order to reach
the determined thickness.
– Press in outer race of tapered roller bearing again
⇒ page 171 and bolt gearbox housing tight.

S01BJXY8W20-5-Speed Manual Gearbox 02R

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S01BJXY8W20-5-Speed Manual Gearbox 02R

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Service

Service Department. Technical Information

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Copyright © 2016 Seat S.A S01BJXY8W20

2.2 Removing and installing gearbox: Toledo 2013 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

1 Input shaft: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Engine code and manufacture date of gearbox

The gearbox identification letters can also be found on the vehicle

2 Overview - power transmission

The -arrows- point forwards.

2 Rep. gr.00 - Technical data

2. Overview - power transmission 3

3 Calculating overall gear ratio “i”

1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear

4 Rep. gr.00 - Technical data

4 Code, engine allocation

4.1 Ibiza 2008 ►, Ibiza ST 2010 ►

4.2 Toledo 2013 ►

4. Code, engine allocation 5

Manual gearbox housing 5-speed 02R

6 Rep. gr.00 - Technical data

5.1 Ibiza 2008 ►, Ibiza ST 2010 ►

5.2 Toledo 2013 ►

6 General repair instructions

6.2 Gaskets, seals

8 Rep. gr.00 - Technical data

6.4 Locking devices

6.5 Bolts, nuts

6.6 Antifriction bearings

6. General repair instructions 9

♦ Check that it is not burred or damaged.

6.8 Synchromesh rings

6.9 Gear wheels

♦ Before engaging the gear wheels, clean thoroughly and heat

6.10 Mobile pinions

6.11 Coupling unit

10 Rep. gr.00 - Technical data

7 Safety precautions for vehicles with

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

7. Safety precautions for vehicles with start/stop system 11

⇒ “1.9 Removing and installing clutch master cylinder”,

1.1 Clutch mechanism: assembly overview

12 Rep. gr.30 - Clutch

I - Assembly diagram - pedal

1. Clutch mechanism: repairs 13

1.2 Assembly overview - pedal cluster

1 - Bulkhead of the plenum

14 Rep. gr.30 - Clutch

1.3 Removing and installing clutch pedal

1. Clutch mechanism: repairs 15

1.4 Removing and installing mounting

♦ Torque wrenches - V.A.G 1331-

♦ Sealing tool - T10249-

16 Rep. gr.30 - Clutch

Right-hand drive vehicles

– Remove the insulating element -arrows-.

♦ During the following work, ensure that no brake fluid lands on

– Clamp off supply hose to master cylinder using hose clamp -

1. Clutch mechanism: repairs 17

Vehicles with start/stop system:

When working in footwell, cover carpet with cloths to protect it

– Remove the driver side foot well cover ⇒ Bodywork, interior