D4B802C0BA3-6-Speed Manual Gearbox 0AJ

Edition 11.2016 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.

00 - Technical data 30 - Clutch 34 - Controls, housing 35 - Gears, shafts 39 - Final drive - differential

Protected by copyright. Copying for private or commercial 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.

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.

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016

1.1 1.1

Safe Safety ty prec precau auti tion ons s for for work workin ing g on vehi vehicl cles es with with star startt-st stop op syst system em . . . . . . . . . . . . . . . . . .

2.1 2.1

Gear Gearbo box x cod codes es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

3.1 3.1

Gene Genera rall repa repair ir note notes s . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .

3

4.1 4.1 4.2 4.2 4.3 4.3

Fill Fillin ing g quan quanti tity ty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Allo Alloca cati tion on gear gearbo box x - engi engine ne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rati Ratio o cal calcu cula lati tion on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 6 6

5.1 5.1

Tran Transm smis issi sion on layo layout ut - fro front nt-w -whe heel el driv drive e . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .

7

6.1 6.1

Fitt Fittin ing g loca locati tion on over overvi view ew - ele elect ctri rica call com compo pone nent nts s . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .

9

1.1 1.1 1.2 1.2 1.3 1.3 1.4 1.4 1.5 1.5 1.6 1.6 1.7 1.7 1.8 1.8 1.9 1.9 1.10 1.10 1.11 1.11 1.12 1.12 1.13 1.13 1.14 1.14 1.15 1.15 1.16 1.16

Loca Locati tion on over overvi view ew - clu clutc tch h mec mecha hani nism sm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Asse Assemb mbly ly over overvi view ew - ped pedal al clus cluste terr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Asse Assemb mbly ly over overvi view ew - clu clutc tch h hyd hydra raul ulic ics s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Asse Assemb mbly ly over overvi view ew - clu clutc tch h rel relea ease se mech mechan anis ism m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Remo Removi ving ng and and ins insta tall llin ing g bea beari ring ng bush bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Clut Clutch ch peda pedal: l: remo removi ving ng and and ins insta tall llin ing g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Remo Removi ving ng and and ins insta tall llin ing g ove overr-ce cent ntre re spri spring ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Remo Removi ving ng and and inst instal alli ling ng retu return rn spri spring ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Remo Removi ving ng and and ins insta tall llin ing g mou mount ntin ing g bra brack cket et . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Removi Removing ng and and inst install alling ing maste masterr cyli cylind nder er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Removi Removing ng and and instal installin ling g clutch clutch slave slave cylind cylinder er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Removi Removing ng and and instal installin ling g lines lines for clutch clutch hydra hydrauli ulics cs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Bleedi Bleeding ng clutch clutch mecha mechanis nism m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Checki Checking ng clutch clutch maste masterr cylind cylinder er and clutch clutch slave slave cylind cylinder er . . . . . . . . . . . . . . . . . . . . . . . . 34 Removi Removing ng and and instal installin ling g clutch clutch posit position ion sender sender G476 G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Repair Repair the clutch clutch relea release se assem assembly bly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.1 2.1 2.2 2.2

Protected by copyright. Copyin g for privat e or commercial purposes, in part or in whole, is not Expl Explod oded ed view view - clu clutc tch hSprivate uni unit t . . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. permitted unless authorised by S EAT S.A. .A. SEAT SEAT S.A does not guarantee or accept any liability with respect the ovin correctness correctness o off information informa tion in this.document. Clut Clutch ch:: torem remov ing g and and inst instal alli ling ng . . . . . Copyright . . . . . by . .SEAT . . . S.A. . .. .. .. .. .. .. .. .. .. ..

1

. .. .. . .. . .. .. .. .. .

37 38

1.1 1.1 1.2 1.2 1.3 1.3 1.4 1.4 1.5 1.5 1.6 1.6 1.7 1.7 1.8 1.8 1.9 1.9 1.10 1.10

Inst Instal alla lati tion on posi positi tion on:: Gea Gearr shif shiftt mec mecha hani nism sm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Over Ov ervi view ew - sel selec ecto torr mec mecha hani nism sm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Asse Assemb mbly ly over overvi view ew - gea gearr leve leverr knob knob and and cove coverr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expl Explod oded ed view view - sel selec ecto torr mec mecha hani nism sm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remo Removi ving ng and and inst instal alli ling ng gear gear knob knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Gear sele select ctio ion n mech mechan anis ism: m: remo removi ving ng and and fitt fittin ing g . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . Adju Adjust stin ing g sel selec ecto torr mec mecha hani nism sm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Gear mech mechan anis ism: m: veri verifi fica cati tion on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seal Seal for for the the sele select ctor or shaf shaft: t: repl replac acem emen entt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Gear mecha mechanis nism: m: repa repairi iring ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 44 45 46 47 49 55 57 57 59

2.1 2.1

Spec Specif ifie ied d tor torqu ques es for for gear gearbo box x . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .

62

Contents

i


ii

2.2 2.2 2.3 2.3

Remo Removi ving ng gear gearbo box x . . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . Inst Instal alli ling ng gear gearbo box x . .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .

62 72

3.1 3.1

Expl Explod oded ed view view - asse assemb mbly ly moun mounti ting ngs s ........................................

79

5.1 5.1 5.2 5.2 5.3 5.3 5.4 5.5 5.5 5.6 5.6 5.7 5.8 5.9

Sche Schema mati tic c ove overv rvie iew w - gear gearbo box x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Syst System em over overvi view ew - gea gearr box box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Asse Assemb mbly ly over overvi view ew - sel selec ecto torr uni unitt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Assemb Assembly ly overvi overview ew - input input shaft, shaft, outpu outputt sha shafts fts,, diff differ eren entia tial, l, select selector or rods rods . . . . . . . . . . . . . . 85 Asse Assemb mbly ly over overvi view ew - sele select ctor or fork forks s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Gear Gearbo box: x: disa disass ssem embl bly y and and asse assemb mbly ly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Explod Exploded ed view view - gearb gearbox ox housi housing ng cover cover and 5th/6t 5th/6th h gea gearr . . . . . . . . . . . . . . . . . . . . . . . . . . 103 103 Repair Repair select selector or forks forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 105 Repair Repairing ing select selector or unit unit . . . . . . . . . . . . . . . . .commercia . . . . . l.purposes, . . . . . in. part . . or . .in. whole, . . . .is .not. . . . . . . . . . . . . 108 108 Protected by copyright. Copying for private or commercial 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.

6.1 6.2 6.3 6.4

Assemb Assembly ly overvi overview ew - clut clutch ch housi housing ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assemb Assembly ly overvi overview ew - gear gearbox box housi housing ng and and clutch clutch housin housing g . . .. . .. . .. . .. . .. . .. . .. . . Assemb Assembly ly over overvie view w - gear gearbox box housi housing ng cover cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Repairing ing the gear gearbox box housi housing ng cover cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1

Checki Checking ng gear gear oil level level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 118

1.1 1.2 1.3

Assemb Assembly ly over overvie view w - input input shaft shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 120 Disass Disassemb embly ly and and assem assembly bly of the input input shaft shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 123 Input Input sha shaft ft oil oil sea seal: l: rep replac lacem ement ent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 131

2.1 2.2

Assemb Assembly ly overvi overview ew - outp output ut shaft shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 133 Disma Dismantl ntling ing and and asse assembl mbling ing outpu outputt sha shaft ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 135

1.1 1.2 1.3

Locat Location ion overvi overview ew - sea seals ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 141 Renewi Renewing ng left left oil oil sea seall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 142 Renewi Renewing ng right right oil seal seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 143

2.1 2.2 2.3

Assemb Assembly ly over overvie view w - differ differen entia tiall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 146 Differ Differen entia tial: l: asse assembl mbly y and and disass disassem embly bly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 147 Differ Differen entia tial: l: Adju Adjust st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 152

Contents

111 111 112 112 114 114 115 115


(ERL003213; Edition 11.2016)

Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised 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.

1. Safety instructions

1


I I Identification letters

I I Day

I I I I Month Year (2002) of manufacture

Additional Additional data identify the the factory where where the unit was built.

The gearbox code is also included on the vehicle data stickers.

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.

2

Rep. gr.00 - Technical data


Extremely careful way of working as well as the highest possible cleanliness are necessary to ensure the trouble free repairing of the gearbox. Furthermore, the tools must be in perfect condition. Naturally, the customary basic safety rules must be observed during repair work. A number number of generally generally valid instructions applicable for the various repair procedures - which were formerly repeated a number of times at numerous places in the workshop manual - are summar‐ ised here. These instructions are valid for this Repair Manual,

For a complete list of special tools used in this Workshop Manual ⇒ Workshop equipment and special tools

♦ When install installing ing the manual manual gearb gearbox, ox, ensure ensure that that the dowel dowel sleeves between the engine and gearbox are positioned cor‐ rectly. ♦ Clean Clean contact contact surfaces surfaces on fitting fitting blocks, blocks, suppor supports ts or waxed components. The surfaces must be completely free from wax or grease. ♦ Allocate Allocate bolts bolts and and other other compo componen nents ts using using ⇒ Electron Electronic ic parts parts catalogue (ETKA) . ♦ If the gearb gearbox ox is repair repaired, ed, fill fill with gear oil.

After removing gaskets and seals, always inspect contact surface of housing or shaft for burrs resulting from removal or for other signs of damage. ♦ Thoroug Thoroughly hly clean clean parting parting surface surfaces s and apply apply sealant sealant . ♦ Allocatio Allocation n ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA (ETKA)) ♦ Before Before installin installing g the oil seal, seal, fill the space space between between the sealin sealing g lips halfway with sealing grease -arrow-. ♦ For grea grease se allocat allocation, ion, refer refer to ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted♦ unless authorise authorised d by SEATof SEAT S.A does not guarantee or accept any liability The open open side oS.A. f the seals should should face face the liquid liquid to bewith retain retained. ed. respect to the correctness of information in this document. Copyright by SEAT S.A.

♦ Lightly oil the O-rings before installation, to prevent prevent them them from from being pressed together during installation.

♦ Thoroughly Thoroughly clean clean housing housing joint joint surfaces surfaces before before applying applying seal‐ ant . ♦ Apply Apply sealant sealant evenl evenly y and not too too thickly. thickly. ♦ Allocatio Allocation n ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA (ETKA)) ♦ Breather Breather holes holes must rema remain in free free of sealan sealantt .

3. Repair notes

3


♦ Replac Replace e safety safety rings. rings. ♦ Do not over-exp over-expand and safety safety rings rings.. ♦ The securin securing g rings rings must be perfectl perfectly y seated seated in their groove groove.. ♦ Replace Replace split split pins. Install Installatio ation n position: position: the the groove groove must face face parallel to the direction in which force is transferred.

♦ Loosen Loosen and tighte tighten n bolts and and securing securing nuts nuts for covers covers and housings diagonally. ♦ For delicat delicate e parts, parts, e.g. the the clutch clutch press, press, do not not tilt them them and always loosen the bolts gradually and in diagonal sequence ♦ The specified specified torque values listed apply to unlubricated unlubricated nuts, nuts, bolts and screws. ♦ Renew Renew self-lockin self-locking g nuts and and bolts after after each each removal. removal. ♦ Contact Contact surfaces surfaces,, bolts and nuts nuts for all threa threaded ded joints joints must must be waxed when fitted if necessary. ♦ Use a thread thread chaser chaser to clear clear residua residuall locking locking fluid from from all threaded holes into which self-locking self-lo cking bolts are to be screwed. Otherwise there is a danger of the bolts shearing off the next time they are removed. ♦ Check Check pitch of thread, thread, to ensure ensure correc correctt thread thread chaser chaser is used to clean threads and to ensure the threads are not damaged.

♦ Lubrica Lubricate te all bearing bearings s with gear gear oil before before installin installing. g. ♦ Protected Install by the thcopyright. e new Copying conical bearings bearing s purposes, unchanged uncha without without for roller private or commercial purpo ses,nged in part orand in whole, is not greasing it. 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.

♦ Install Install needle needle bearings bearings with letter lettered ed side (thicker (thicker metal) metal) to‐ wards fitting drift. ♦ Conical Conical roller roller bearin bearings gs fitted fitted into one one same shaft shaft must be re‐ re‐ placed together. They must have the same manufacturer. ♦ The inner inner races races must must be heated heated to abou aboutt 100 °C before before the the installation with the inductive heater unit - VAS 6414- . ♦ Do not confuse confuse the outsid outside e and inside inside rings rings of the bearing bearing with the rings from other bearings of the same size. The bearings come in matched pairs.

4



♦ Check Check shim settings settings at variou various s points, points, using a microm micrometer eter.. The various thicknesses make it possible to achieve the exact shim thickness required. ♦ Check Check that that it is not not burred burred or damag damaged. ed. ♦ Only Only fit fit shims shims in per perfec fectt state. state.

♦ Do not mix mix up. Do not mix mix up synchro synchronise niserr rings rings from differe different nt gears. ♦ Check Check for wear and repla replace ce if neces necessary sary.. ♦ Check grooves grooves -arrow -arrow 1- of synchro synchro ring -A- and and inner inner ring for flat spots (worn grooves). ♦ If synchrosynchro-ring rings s are coated, coated, coating coating must must not be damaged damaged.. ♦ If an intermed intermediate iate ring ring -B- is installe installed, d, check check the outer outer friction friction surface -arrow 2- and inner friction surface -arrow 3- of this intermediate ring for »scoring«, »signs »si gns of abnormal wear« and »blue discolouration (due to overheating)«. ♦ Check the the cone of the synchromeshed synchromeshed gear gear for »scoring« and »signs of abnormal wear«. ♦ Moisten Moisten synchro synchromesh mesh mechan mechanism ism with gear gear oil before before instal‐ instal‐ ling.

♦ Before Before installin installing, g, clean clean and heat heat with the inductiv inductive e heater heater VAS 6414- to maximum 100° C. ♦ Note correct correct installati installation on position. position.

♦ After assemb assembly, ly, check check synchrome synchromeshed shed gears gears for slight slight play, play, or for freedom of movement. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Disconnect vehicle battery battery ⇒ Electrical system; Rep gr. 27 ; or accept any liability with permitted unless authorised authorise d by SEAT S.A. SEAT S.ARep. does.not guarantee respect to the correctness of information Battery; Disconnecting and connecting battery in. this document. Copyright by SEAT S.A. When the battery is re-connected, observe the ⇒ Electrical sys‐ tem; Rep. gr. 27 ; Battery; Disconnecting Disconnec ting and connecting battery .

♦ Ensure Ensure that the the pressure pressure plate plate is kept straigh straight: t: loosen loosen and tighten bolts in a diagonal sequence and in several gradual stages. ♦ If the clutch clutch has burnt burnt out, thorou thoroughly ghly clean clean the clutch clutch housing housing as well as the friction surface of flywheel with a cloth to reduce the smell of burnt linings.

3. Repair notes

5


Capacity of manual gearbox

2.3 litres

6-speed manual gearbox

0AJ

Correspondence

Type

Leon 2013

Engi Engine ne 1.2 1.2 TSI TSI 77 kW, kW, 1,4L TSI 90 kW / 92 kW / 103kW Gear ratio: Z 2 : Z 1

1.0 TSI 85 kW

1.0 TSI 85 kW

1.2 TSI 81 kW, 1.4L TSI 81 kW / 92 kW

Mechanism

73 : 18 = 4,056

73 : 18 = 4,056

73 : 18 = 4,056

73 : 18 = 4,056

1st gear

47 : 13 = 3,615

49 : 13 = 3,769

47 : 13 = 3,615

47 : 13 = 3,615

2nd gear

37 : 19 = 1,947

43 : 22 = 1,955

37 : 19 = 1,947

37 : 19 = 1,947

3rd gear

41 : 32 = 1,281

41 : 32 = 1,281

41 : 32 = 1,281

41 : 32 = 1,281

4th gear

36 : 37 = 0,973

36 : 37 = 0,973

36 : 37 = 0,973

36 : 37 = 0,973

5th gear

35 : 45 = 0,778

35 : 45 = 0,778

35 : 45 = 0,778

35 : 45 = 0,778

6th gear

31 : 48 = 0,646

31 : 48 = 0,646

34 : 53 = 0,642

31 : 48 = 0,646

speed in re‐ 24 : 11 x 35 : 24 = 24 : 11 x 35 : 24 = 24 : 11 x 35 : 24 = 24 : 11 x 35 : 24 = verse 3.181 3.181 3.181 3.181 Glean following data from ⇒ Electronic parts catalogue (ETKA) : ♦ Indivi Individu dual al gear gear ratio ratios s ♦ Gear oil ♦ Alloca Allocatio tion n of of clutc clutch h type type

Driving gear

TG1 = 46

ZA1 = 24

Driven gear

TG2 = 33

ZA2 = 70

i = ZG2 : ZG1 1) iG = Gear ratio = ZG 2 : ZG1 = 33 : 46 = 0.717 i = Final drive ratio = ZA 2 :Protected ZA1 =by70 : 24 = 2.917 copyright. Copying for private or commercial purposes, in part or in whole, is not A

permitted unless authorised authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

the2.917 correctness of information in this document. Copyright by SEAT S.A. itotal. = overall ratio = i G x A i = respect 0.717to x = 2.091

1) T1 = No. of teeth on driving gear, T 2 = No. of teeth on driven gear

6



-Arrows- point in direction of travel.


-Arrows- point in direction of travel.

5. Overview of the drive force

7


Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised 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.

8



❑ Fittin Fitting g locati location on:: benea beneath th starter ❑ Remo Remove ve and and inst instal alll ⇒ page 85

❑ Loca Locati tion on:: In area area of se‐ se‐ lector unit beneath an‐ gled rod for securing selector shaft ❑ Remo Remove ve and and inst instal alll ⇒ page 85

Location: in passenger compartment on clutch master cylinder. Removal and installation of the sender for the clutch position G476- ⇒ page 34 . 34 . Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised by SEA T S.A. SEAT S.A does S.A does not guarantee or accept any liability with respect to the correctness o f information in this t his document. Copyright by SEAT S.A.

6. Electrical components

9



10

Rep. gr.30 - Clutch



1. Clutch mechanism

11


❑ Remo Remove ve and and inst instal alll ⇒ page 28 ❑ Remo Remove ve and and inst instal alll ⇒ page 17 ❑ Cabl Cable e mus mustt not not be greased ❑ To rem remov ove e pipe pipe,, pull pull out out clip to stop. ❑ Can be drive driven n in in full fully y be‐ be‐ fore the line is installed ❑ Self Self--adhesi esive ❑ Rene Renew w aft after er remo removi ving ng the clutch master cylin‐ der ❑ Glue Glue onto onto clu clutc tch h mas maste ter r cylinder

❑ Can Can be be che check cked ed with with it in ⇒ Vehicle diagnostic aul t tester Gui ded f aul


f i ndi ng

❑ Allo Alloca cati tion on ⇒ Elec Electr tron onic ic parts catalogue (ETKA) ❑ Remo Remove ve and and inst instal alll ⇒ page 34 ❑ Must Must be rene renewe wed d ifif re‐ re‐ moved ❑ Cable Cable must must not not be grease greased d

❑ ❑ ❑ ❑ ❑

For mount mounting ing brack bracket et to bulkhe bulkhead ad 3 Units Self Self--lock lockin ing g Must Must be be ren renewe ewed d ifif rem remove oved d 25 Nm

❑ ❑ ❑ ❑

2 Units Inst Instal alle led d on both both sid sides es Only fitted fitted in in conjuncti conjunction on with with over-cen over-centre tre spring spring.. Cable Cable must must not not be grease greased d

❑ For For clut clutch ch peda pedall ❑ Remove and install ⇒ page 24

12

Rep. gr.30 - Clutch

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ❑ Using drift - VW 207- drive drive bushes for the studs used to fasten fasten the mounting mounting bracket bracket onto the bulkhead, bulkhead, into the holes in the mounting bracket ❑ Fitted Fitted dep depen endin ding g on desig design n status status ❑ Remo Remove ve and and inst instal alll ⇒ page 22 ❑ Do not not grea grease se seat seat on moun mounting ting bracket bracket ❑ For For mast master er cyli cylind nder er ❑ Must Must be rene renewed wed if remove removed d ❑ Cabl Cable e must must not not be be grea grease sed d ❑ ❑ ❑ ❑

Fitted Fitted dep depen endin ding g on desig design n status status Different versions available; for correct correct version version refer to ⇒ Electronic parts catalogue (ETKA) .⇒ Remo Remove ve and and inst instal alll ⇒ page 19 Protected by copyright. Copying for private or commercial 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 Cabl Cable e must must not not be be grea grease sed d permitted unless authorised respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Cabl Cable e must must not not be be grea grease sed d ❑ ❑ ❑ ❑ ❑

Fitted Fitted dep depen endin ding g on desig design n status status For moun mountin ting g retu return rn spring spring Fit Fit ont onto o clu clutc tch h ped pedal al Grease Grease when mountin mounting g retur return n sprin spring. g. Grease Grease ⇒ Electron Electronic ic Parts Parts Catalogu Catalogue e (ETKA) (ETKA)

❑ for plunger plunger of the the clutch clutch master master cylind cylinder er ❑ Must Must be rene renewed wed if remove removed d ❑ Cabl Cable e must must not not be be grea grease sed d ❑ Remo Remove ve and and inst instal alll ⇒ page 18 ❑ Cabl Cable e must must not not be be grea grease sed d

❑ Cabl Cable e must must not not be be grea grease sed d ❑ ❑ ❑ ❑

For For clut clutch ch peda pedall Fitted Fitted dep depen endin ding g on desig design n status status Installing and removing removing ⇒ Removing Removing and installing installing over-centre over-centre spring spring ⇒ page 19 . 19 . Cabl Cable e must must not not be be grea grease sed d

❑ Only fitted fitted in conju conjunctio nction n with extension extension spring. spring. ❑ Cabl Cable e must must not not be be grea grease sed d

1. Clutch mechanism

13


❑ 20 Nm ❑ Blee Bleedi ding ng clu clutc tch h mech mecha‐ a‐ nism ⇒ page 33 ❑ Tigh Tighte teni ning ng tor torqu que e ⇒ page 33 . 33 .

❑ Must Must be be fit fitte ted d in in sup suppl ply y hose ❑ If they they are are dam damag aged ed,, they must be renewed together with the supply hose ❑ Remo Remove ve and and inst instal alll ⇒ page 28 ❑ To rem remov ove e pipe pipe,, pull pull out out clip to stop. ❑ Can be drive driven n in in full fully y be‐ be‐ fore the line is installed ❑ Repl Replac ace e if dam damag aged ed ❑ Inst Instal alll on line line con conne nec‐ c‐ tion ❑ Lubric Lubricate ate with with brake brake flu‐ flu‐ id before installing ❑ Whether Whether a seal seal or an O-rin O-ring g is used depen depends ds on the the type of connec connection tion ⇒ page 31 ❑ Allocatio Allocation n ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) (ETKA) Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised 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.

❑ For For pipe pipe/h /hos ose e asse assemb mbly ly ❑ Different Different supports supports for LHD LHD and and RHD RHD vehicles vehicles.. ❑ Allocatio Allocation n ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) (ETKA) ❑ Different Different lengths lengths for for LHD LHD and and RHD RHD vehicl vehicles. es. ❑ Allocatio Allocation n ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) (ETKA) ❑ Remo Remove ve and and inst instal alll ⇒ page 31 ❑ Rep Replace lace if damaged amaged

14

Rep. gr.30 - Clutch

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ❑ ❑ ❑ ❑

Instal Installl on on line line connec connectio tion n Lubricat Lubricate e with with brake brake fluid before before insta installing lling Whether Whether a seal seal or an O-rin O-ring g is used depen depends ds on the the type of conne connection ction ⇒ page 31 Allocatio Allocation n ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) (ETKA)

❑ To rem remove ove pipe, pipe, pull pull out out clip clip to stop stop.. ❑ Can be be driven driven in in fully fully before before the line line is instal installed led ❑ Remo Remove ve and and inst instal alll ⇒ page 28

❑ Remo Remove ve and and inst instal alll ⇒ page 28 ❑ Blee Bleedi ding ng clu clutc tch h mech mecha‐ a‐ nism ⇒ page 33 ❑ Tigh Tighte teni ning ng tor torqu que e ⇒ page 33 . 33 .

❑ Must Must be be fitt fitted ed in supp supply ly hose ❑ If they they are are dam damag aged ed,, they must be renewed together with the supply hose ❑ Remo Remove ve and and inst instal alll ⇒ page 28 ❑ Pull Pull out out cli clip p to to st stop to re‐ move and install pipe/ hose line ❑ Repl Replac ace e if dam damag aged ed Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not ❑ Inst Instal alll on on lin line e con conne nec‐ c‐ permitted unless authorised 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. tion ❑ Lubr Lubric icat ate e with with bra brake ke flu flu‐‐ id before installing ❑ Whether Whether a seal seal or an O-rin O-ring g is used depen depends ds on the the type of conne connection ction ⇒ page 31 ❑ Allocatio Allocation n ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) (ETKA) ❑ For For pipe pipe/h /hos ose e asse assemb mbly ly ❑ Allocatio Allocation n ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) (ETKA) ❑ Remo Remove ve and and inst instal alll ⇒ page 31

1. Clutch mechanism

15


❑ ❑ ❑ ❑ ❑

Repl Replac ace e if dam damag aged ed Instal Installl on on line line conne connecti ction on Lubricate Lubricate with brake brake fluid fluid before before insta installing lling Whether Whether a seal seal or an O-rin O-ring g is used depen depends ds on the the type of connec connection tion ⇒ page 31 Allocatio Allocation n ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) (ETKA)

❑ Pull Pull out out clip clip to stop stop to rem remove ove and and install pipe/hose pipe/hose line ❑ 20 Nm

❑ To remo remove ve and and ins insta tall ll,, remove gearbox ❑ Remo Remove ve and and ins insta tall ll to‐ to‐ gether with clutch re‐ lease bearing and guide sleeve ⇒ page 35 to 35 to ⇒ page 36 ❑ Remo Remove ve any any tra trace ces s of of grease ❑ Grea Grease se con conta tact ct sur surfa face ce of ball-head pin with grease for clutch plate splines ❑ For For grea grease se all alloc ocat atio ion, n, refer to ⇒ Electronic parts catalogue (ET‐ KA) .


❑ Remo Remove ve and and ins insta tall ll to‐ to‐ gether with clutch re‐ lease lever and guide sleeve ⇒ page 35 ❑ Do not not was wash h out out bear bear‐‐ ing; wipe only ❑ Repl Replac ace e col colla lars rs that make a noise ❑ Must Must be rene renewe wed d ifif re‐ re‐ moved ❑ 5 Nm + +90° ❑ Remo Remove ve and and inst instal alll ⇒ page 28

❑ Repl Replac ace e afte afterr remo remova vall ⇒ page 131 ❑ Remo Remove ve and and inst install all together together with release bearing and clutch release lever ⇒ page 35

16

Rep. gr.30 - Clutch


❑ ❑ ❑ ❑ ❑

To remo remove ve and and insta install, ll, remove remove gearb gearbox ox Remove Remove any any trace traces s of of grea grease se Grease contact surface surface of ball-head ball-head pin with grease grease for clutch plate plate splines For grea grease se allocat allocation, ion, refer refer to ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) (ETKA) . 20 Nm

❑ Secu Secure re to clut clutch ch leve lever r

Disconnect vehicle battery battery ⇒ Electrical system; Rep. Rep. gr. 27 ; Battery; Disconnecting and connecting battery . – Compress catches -arrows-arrows- and and take out pin -1- towards towards right right side.

Protected by copyright. Copying for private or commercial commercial purposes, in part or in whole, is not permitted unless authorised 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.

– Turn plunger plunger of master master cylinder so that recesses -1-1- or pin -2- are visible. Recesses -1- and pin -2- are facing the same direction. – Remove bearing bearing bush -A- from recesses recesses -1-.

– Turn plunger plunger of master master cylinder so that recesses -1-1- or pin -2- are visible. Recesses -1- and pin -2- are facing the same direction. – Fit and swivel bearing bearing bush bush -A- into recesses recesses -1-. – Connect plunger/clutch plunger/clutch master master cylinder cylinder with the clutch pedal using a new pivot pin. – Connect vehicle vehicle battery ⇒ Electrical system; system; Rep. gr. 27 ; Battery; Disconnecting and connecting battery .

1. Clutch mechanism

17


– Push driver's driver's seat as far back back as possible. possible. – Move steering steering wheel up as far as it will go, go, making use of of full range of steering column adjuster. – If fitted, remove remove footwell footwell cover on driver side ⇒ General body repairs, interior; Rep. gr. 68 ; Compartments/covers .

– Remove the knee knee airbag airbag -1- on the driver's side side ⇒ Chassis interior assembly work ; Rep. gr. 69 ; Knee airbags .

– Switch off ignition ignition and all electrical electrical consumers, consumers, and remove remove ignition key.

– Remove the footwell vent -1- on the the driver driver side side ⇒ heating, airconditioning conditioning system; Rep. gr. 87 ; air ducting system; Assem‐ bly overview - air ducting and - distribution to interior .

– Compress catches -arrows-arrows- and take out pin -1- towards towards right right side.

–

Protected by copyright. copyright. Copying f or or private or commercial purposes, in part or in whole, is not permitted unless authorised authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with Remove therespect Servomotor Servomoto r of theof right temperature temperatur e valve - V159to the correctness information in this document. Copyright by SEAT S.A.

⇒ Heating, air conditioning; Rep. gr. 87 ; Servomotors; Servomotor of the right temperature valve V159: remove and install .

– Remove return return spring from mounting mounting bracket ⇒ page 22 or 22 or remove over-centre spring from mounting bracket ⇒ page 19 . 19 . – If it is fitted near the the clutch pedal, pedal, remove the the bracket for the the control unit for parking sensor - J446- / control unit for park assist - J791- ⇒ Electrical system; Rep. Rep. gr. 27 ; Park assist system; Assembly overview - Park assist system . Do not un‐ couple cable connections.

18

Rep. gr.30 - Clutch


-1- = 14 mm hexagon bit.

A 14 mm hexagon key can be used instead of the 14 mm hexagon bit

•

The pivot pivot pin for for the the clutch clutch pedal pedal must must be be turned turned to the left to to stop, -direction of arrow-.

– Move the clutch clutch pedal slightly slightly so that the pivot pivot pin can be pulled out.

Install in the reverse order of removal, observing the following: -1- = 14 mm hexagon bit.

A 14 mm hexagon key can be used instead of the 14 mm hexagon bit

•

Rene Renew w pivo pivott pin pin afte afterr remo remova val. l.

– Depress clutch pedal slightly slightly and push new new pivot pin through through to stop. – Turn pivot pin pin to right to stop, stop, -direction -direction of arrow-.

Protected by copyright. Copying for private or commercial purposes, 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 Locki Locking ng devi devices ces -A-A- must must audi audibly bly enga engage ge. . respect to the correctness of information in this document. Copyright by SEAT S.A.

– Mount return return spring to the mounting mounting bracket ⇒ page 22 , 22 , or mount over-centre spring to the mounting bracket ⇒ page 19 . 19 .

– Install the Servomotor Servomotor of the the right temperature temperature valve valve - V159⇒ Heating, air conditioning; conditionin g; Rep. gr. 87 ; Servomotors; Servomotor of the right temperature valve V159: remove and install .

– If fitted, install the bracket bracket with the the control control unit for for parking parking sen‐ sor - J446- / control unit unit for park assist - J791- ⇒ Electrical system; Rep. gr. 27 ; Park assist system; Assembly Assembly overview - Park assist system . Do not uncouple cable connections. – Install the footwell footwell vent on the driver side ⇒ heating, air-con‐ air-con‐ ditioning; Rep. gr. 87 ; air ducting system; Assembly overview overview - air ducting and - distribution to interior .

– Install driver-side driver-side knee knee airbag ⇒ General General body repairs, repairs, interi‐ or; Rep. gr. 69 ; knee airbags; Removing and installing the knee airbag with fuse .

– Push driver's driver's seat as far back back as possible. possible.

1. Clutch mechanism

19

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Move steering steering wheel up as far as it will go, go, making use of of full range of steering column adjuster. – If fitted, remove remove footwell footwell cover on driver side ⇒ General body repairs, interior; Rep. gr. 68 ; Compartments/covers .


Disconnect vehicle battery battery ⇒ Electrical system; Rep. Rep. gr. 27 ; Battery; Disconnecting and connecting battery .

Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorise SEAT SEAT does not guarantee – Remove the footwell vent -1-authorised on the thdebydriver dr iverS.A. side side ⇒S.A heating, air- or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A. conditioning conditioning system; Rep. gr. 87 ; air ducting system; Assem‐ bly overview - air ducting and - distribution to interior .

– Remove the diagnosis diagnosis interface interface for the data bus - J533J533- from the bracket -1- ⇒ electrical system; system; Rep. gr. 97 ; control control units; Installing and removing the diagnosis interface for the J533 data bus and push it to one side.

– Remove bolt bolt -2-, detach crash crash bar -1-1- and push to one side. side. – If it is fitted near the the clutch pedal, pedal, remove the the bracket for the the control unit for parking sensor - J446- / control unit for park assist - J791- ⇒ Electrical system; Rep. Rep. gr. 27 ; Park assist system; Assembly overview - Park assist system . Do not un‐ couple cable connections.

20

Rep. gr.30 - Clutch

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Compress catches catches -arrows-arrows- and take out out pivot pin -1-1- for plunger/clutch master cylinder towards right side.

– If present, unhook unhook and remove remove spring spring -1- whilst pushing pushing the clutch pedal in -direction of arrow B-. – Return clutch pedal to resting resting position. position. – Pull clutch clutch pedal pedal in -direction of arrow arrow A-, unhook and remove over-centre spring -2-.

Install in the reverse order of removal, observing the following: •

The bearing bearing shell shells s -arrow-arrow- for the the pins pins -1-1- are installed installed..

– Pull clutch pedal pedal towards vehicle vehicle interior interior (⇒ -arrow -arrow A- in pre‐ vious Fig.). – Place pins -1-1- in the supports supports -2- of the the mounting bracket. – Place bearing bearing -3- in the the support -4-4- of the clutch pedal. Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not • unless When thed by clutch clutch pedal ped al is pdoes ressed ed in -directio -dirorection nany ofliability arro arrow w (⇒ permitted authorise authorised SEAT S.A. SEAT S.Apress not guarantee accept withB- (⇒ respect to the correctness information in this document. Copyright SEATtowards S.A. previous Fig.),ofthe over-centre spring flips by over the

mounting bracket. – Connect plunger/clutch plunger/clutch master master cylinder cylinder with the clutch pedal using a new pivot pin. – If fitted, install the bracket bracket with the the control control unit for for parking parking sen‐ sor - J446- / control unit unit for park assist - J791- ⇒ Electrical system; Rep. gr. 27 ; Park assist system; Assembly Assembly overview - Park assist system . Do not uncouple cable connections.

1. Clutch mechanism

21

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Position the crash crash bar -1-1- and fully tighten tighten the screw -2- ⇒ body installation installation tasks, interior; Rep. gr. gr. 70 ; central tube for dash panel: Assembly overview - central tube for dash panel . – Remove the diagnosis diagnosis interface interface for the data bus - J533J533- from the bracket bracket ⇒ electrical system; Rep. Rep. gr. 97 ; control units; units; Installing and removing the diagnosis interface for the J533 data bus and push it to one side. – Install the footwell footwell vent on the driver side ⇒ heating, air-con‐ air-con‐ ditioning; Rep. gr. 87 ; air ducting system; Assembly overview overview - air ducting and - distribution to interior .

– Install driver-side driver-side knee airbag ⇒ General body repairs, repairs, interi‐ or; Rep. gr. 69 ; knee airbags; Removing and installing installin g the knee airbag with fuse .

– Connect vehicle vehicle battery ⇒ Electrical system; system; Rep. gr. 27 ; Battery; Disconnecting and connecting battery .

– Push driver's driver's seat as far back back as possible. possible. – Move steering steering wheel up as far as it will go, go, making use of of full range of steering column adjuster. – If fitted, remove remove footwell footwell cover on driver side ⇒ General body repairs, interior; Rep. gr. 68 ; Compartments/covers .



– Remove the footwell vent -1- on the the driver driver side side ⇒ heating, airconditioning conditioning system; Rep. gr. 87 ; air ducting system; Assem‐ bly overview - air ducting and - distribution to interior .


22

Rep. gr.30 - Clutch

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Compress catches -arrows-arrows- and and take out pin -1- towards towards right right side.

– Swivel clutch pedal towards rear -arrow-, unhook return spring -1- and remove.

Install in the reverse order of removal, observing the following:


•

For the the return return spring spring -1- (⇒ (⇒ previou previous s Fig.) Fig.) lightly lightly grease grease the following areas:

•

Sliding Sliding bush bush on the mount mounting ing area areas s -A- for for the retur return n spring. spring.

•

Fillet -B-

•

Fillet -C -C-.

•

For grease grease alloca allocation tion,, refer refer to ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) .

– Swivel clutch pedal pedal in -direction -direction of arrowarrow- and hook hook up return spring -1- (⇒ previous Fig.). – Connect plunger/clutch plunger/clutch master master cylinder cylinder with the clutch pedal using a new pivot pin. – Install the footwell footwell vent on the driver side ⇒ heating, air-con‐ air-con‐ ditioning; Rep. gr. 87 ; air ducting system; Assembly overview overview - air ducting and - distribution to interior .

– Install driver-side driver-side knee knee airbag ⇒ General General body repairs, repairs, interi‐ or; Rep. gr. 69 ; knee airbags; Removing and installing the knee airbag with fuse .

– Connect vehicle vehicle battery ⇒ Electrical system; system; Rep. gr. 27 ; Battery; Disconnecting and connecting battery .

1. Clutch mechanism

23


♦ Hose Hose clamp clamps, s, up to 25 mm - 309 30944-

♦ Sealin Sealing g too tooll - T1024 T102499Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised 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.

♦ Torqu Torque e wren wrench ch - V.A. V.A.G G 1331 1331--

– Push driver's driver's seat as far back back as possible. possible. – Move steering steering wheel up as far as it will go, go, making use of of full range of steering column adjuster.

24

Rep. gr.30 - Clutch


– Remove the knee airbag airbag -1- on the the driver's side side ⇒ Chassis interior assembly work ; Rep. gr. 69 ; Knee airbags .


– Remove the footwell footwell vent vent -1-1- on on the driver side ⇒ heating, airconditioning conditioning system; Rep. gr. 87 ; air ducting system; Assem‐ bly overview - air ducting and - distribution to interior . in whole, is not Protected by copyright. Copying for private or commercial purposes, in part or permitted unless authorised 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.

– Take data bus bus diagnostic diagnostic interface - J533J533- -1- out out of bracket ⇒ Electrical system; Rep. Rep. gr. 97 ; Control units; units; Overview Overview of fitting locations - control units , and push to one side.

– Remove bolt bolt -2-, detach crash bar -1-1- and push push to one side. side. – If it is fitted near the the clutch pedal, pedal, remove the the bracket for the control unit for parking sensor - J446- / control unit for park assist - J791J791- ⇒ Electrical system; system; Rep. gr. gr. 27 ; Park Park assist system; Assembly overview - Park assist system . Do not un‐ couple cable connections. – The air filter filter housing must must be completely completely removed removed if the ac‐ cess to the mechanism lines for the clutch movement is hin‐ dered⇒ Rep. gr. 24 ; air filter ⇒ Rep. gr. 23 ; air filter .

1. Clutch mechanism

25


An insulation insulation mat is installed installed in conjunction conjunction with some engines. engines. Appearance Appearance may be different different from that illustrated. illustrated. – Remove insulation insulation mat. Note Note item -1...4-.

– Remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery .

– Using hose hose clamp clamp - 3094- , clamp off supply supply hose hose -2- to clutch master cylinder.

♦ Clamping off the supply hose with the hose clamp - 3094- will cause a permanent deformation. ♦ However, this does not damage the supply hose. ♦ After removing removing the hose hose clamp - 30943094- , the supply supply hose must be returned to its original shape.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless authorised 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.

– Pull clip clip for pipe/hose line -1- all the the way way out and remove pipe/ hose line. – Seal openings. openings. – Disconnect supply supply hose from clutch master cylinder and plug hose using sealing tool - T10249/1- .

26

Rep. gr.30 - Clutch


When working in the footwell, protect the floor covering with cloths from escaping brake fluid. – Unplug electrical electrical connector connector -2- at clutch clutch position sender sender G476- . – Remove nuts nuts -arrows- and and detach mounting mounting bracket bracket -1-.

Install in the reverse order of removal, observing the following: – Renew self-locking self-locking nuts and and seal for clutch master cylinder cylinder after removing. – If fitted, install the bracket bracket with the the control control unit for for parking parking sen‐ sor - J446- / control unit unit for park assist - J791- ⇒ Electrical system; Rep. gr. 27 ; Park assist system; Assembly Assembly overview Protected by copyright. Copying for private or commercial commercial purposes, in part or in whole, is not - Park assist system . S.A. Do SEAT not S.A uncouple cable orconnections. permitted unless authorise authorised d by SEAT does not guarantee accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.

– Insert crash bar bar -1- and and tighten bolt bolt -2- ⇒ General General body re‐ pairs, interior; Rep. gr. 70 ; Dash panel central tube; Assembly overview - dash panel central tube . – Install data bus bus diagnostic interface interface - J533J533- ⇒ Electrical sys‐ tem; Rep. gr. 97 ; Control units; Overview Overview of fitting locations control units . – Remove footwell footwell vent on driver's driver's side ⇒ Heating, air condi‐ condi‐ tioning; Rep. gr. 87 ; Air duct; Assembly overview overview - air routing and air distribution in passenger compartment .

– Install knee airbag airbag on driver's driver's side ⇒ General body repairs, repairs, interior; Rep. gr. 69 ; Knee airbags; Exploded view - knee airbag .

The battery is installed and connected at a later stage.

– Connect pipe/hose pipe/hose assembly assembly -1- to connection connection ⇒ page 30 . 30 . – Connect supply supply hose -2- at clutch master cylinder. •

After removing removing the the hose hose clamp clamp - 30943094- , the supply supply hose hose must must be returned to its original shape.

1. Clutch mechanism

27


– If present, attach the insulation mat in the order -1, 2, 3- around the lines. – Secure the insulation mat mat with the lock washer washer -4-.

– Bleeding clutch clutch mechanism mechanism ⇒ page 33

– Install driver-side driver-side knee airbag ⇒ General body repairs, repairs, interi‐ or; Rep. gr. 69 ; knee airbags; Removing and installing installin g the knee airbag with fuse .

– Install and/or connect battery battery ⇒ Electrical system; system; Rep. gr. 27 ; Battery; Disconnecting and connecting battery .

♦ Mount Mounting ing bra bracke ckett to bulkhe bulkhead ad ⇒ page 12 . 12 .

♦ Carry out Guided fault finding using using ⇒ Vehicle diagnostic tester before you renew the clutch master cylinder with an as‐ sumed fault. ♦ When working in the footwell, protect the floor covering with cloths from escaping brake fluid. – Remove mounting mounting bracket bracket ⇒ page 24 . 24 . – Remove clutch position sender sender - G476G476- ⇒ page 34 . 34 . – Release catches catches -arrows- and press out out pivot pin -2-. -2-. – Detach clutch master master cylinder cylinder -1-. Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not unless authorised by SEAT S.A.observing SEAT S.A doesthe not guarantee or accept any liability with Install in thepermitted reverse order of removal, following: respect to the correctness of information in this document. Copyright by SEAT S.A.

Renew pivot pin after removal. – Install mounting mounting bracket ⇒ page 24 . 24 . – Install clutch position position sender sender - G476- ⇒ page 34 . 34 .

28

Rep. gr.30 - Clutch

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ♦ Hose Hose clamp clamps, s, up to 25 25 mm - 3094 3094--



♦ Before replacing the clutch slave cylinder due a suspected defect, you must first use guided fault finding ⇒ ⇒ Vehicle diagnostic tester. ♦ If slave cylinder is removed from gearbox with pipe/hose as‐ sembly still attached, make sure you do not press clutch pedal. Otherwise, the piston will be pressed out of the slave cylinder and be destroyed. – Remove battery, battery, battery cover cover and battery battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and reconnecting reconnecting the battery .

1. Clutch mechanism

29

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Place lint-free lint-free cloth under under clutch slave cylinder. cylinder. – Release clip -A- with a screwdriver screwdriver and disconnect pipe/hose pipe/hose assembly -B- from connection. – Pull pipe/hose pipe/hose assembly -B-B- out of clutch slave slave cylinder and and seal both openings. – Remove bolts bolts -arrows- and and remove clutch slave cylinder. cylinder.


♦ Grease

Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness information in this document. Copyright by SEAT S.A. all bearing surfaces and ofcontact surfaces.

♦ For grease allocation, refer to ⇒ Electronic parts catalogue (ETKA) . – Fit clutch slave cylinder cylinder -A- and and secure with bolts -arrows-. -arrows-. – Connect pipe/hose pipe/hose assembly assembly -B- ⇒ page 30 . 30 .

– Release clip -3-3- with a screwdriver screwdriver and disconnect pipe/hose pipe/hose assembly -1- from connection -4-.

♦ Instead of the seal -2- it is also possible to install an O-ring ⇒ page 31 . . ♦ Renew seal -2- if damaged. – Press pipe/hose pipe/hose assembly assembly -1- into connection connection -4- so that clip -3- snaps into place. – Pull on pipe/hose pipe/hose assembly assembly to check it is secure. secure.

30

Rep. gr.30 - Clutch


•

1

Lin Line co connectio ction n with with annular lar gr groove -ar -arrow 11-

2

Connection wi with shoulder -arrow 22-

3

Lin Line co connectio ction n wit with h sh shoulde lder -a -arrow 2- an and cir cir‐‐ cumferential groove -arrow 3-

For line line connec connection tion havin having g circumfe circumferent rential ial groove groove -arr -arrow ow 1and -arrow 3-, a seal or O-ring must be set there.

– Bleeding clutch clutch mechanism mechanism ⇒ page 33 – Install battery battery tray, tray, battery and battery battery cover cover ⇒ Electrical sys‐ tem; Rep. gr. 27 ; Battery; Disconnecting Disconnect ing and reconnecting the battery .

♦ Clutch Clutch slave slave cylinder cylinder to gearbox gearbox ⇒ page 10

♦ Hose Hose clamp clamps, s, up to 25 25 mm - 3094 3094--

– Remove complete air filter housing if it prevents prevents access to the lines for clutch clutch mechanism ⇒ Rep. gr. 24 ; Air filter; Removing Removing and installing air filter housing . – Remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery .


1. Clutch mechanism

31


An insulation insulation mat is installed installed in conjunction conjunction with some engines. engines. Appearance Appearance may be different different from that illustrated. illustrated. – Remove insulation insulation mat. Note Note item -1...4-.

– Using hose hose clamp clamp - 3094- , clamp off supply supply hose hose -2- to clutch master cylinder.

♦ Clamping off the supply hose with the hose clamp - 3094- will cause a permanent deformation. ♦ However, this does not damage the supply hose. ♦ After removing removing the hose hose clamp - 30943094- , the supply supply hose must be returned to its original shape. – Pull clip clip for pipe/hose line -1- all the the way way out and remove pipe/ hose line. – Seal openings. openings. – Pull clip -A- all all the way out and and remove pipe/hose pipe/hose line line -B-. – Seal openings. openings.

-Arrows- can be disregarded. – Seal off open open lines and connections connections if necessary necessary with clean clean plugs from engine bung set - VAS 6122- . – Move pipe/hose pipe/hose assembly assembly clear and remove. remove.

Install in the reverse order of removal,

Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with to the correctness of information in this document. Copyright by SEAT S.A. observing therespect following:

– Connect hose/pipe assembly-1assembly-1- to connection of clutch master cylinder and clutch slave cylinder. – Pull on pipe to check it is secure. secure. •

After removing removing the hose hose clamp clamp - 30943094- , the supp supply ly hose hose -2-2must be returned to its original shape.

32

Rep. gr.30 - Clutch


– If present, attach the insulation mat in the order -1, 2, 3- around the lines. – Secure the insulation mat mat with the lock washer washer -4-.

– Bleeding clutch clutch mechanism mechanism ⇒ page 33 – Install battery battery tray and battery battery ⇒ Electrical system; system; Rep. gr. 27 ; Battery; Removing and installing battery .

♦ Brake Brake filling filling and bleed bleeding ing equipm equipment ent - VAS VAS 52345234-


♦ After carrying out work on the hydraulic clutch mechanism, mechanism, the the system must be bled. ♦ When performing the following steps, make mak e sure that no brake fluid escapes onto the gearbox. ♦ Prefilling system is not necessary! ♦ Before bleeding, fill brake fluid reservoir up to “max” marking with brake fluid. ♦ Clutch pedal is at rest position, is not being depressed. ♦ Brake fluid: allocation ⇒ Electronic parts catalogue (ETKA) .⇒ – Remove complete complete air filter filter housing if it prevents prevents access to bleeder valve (-arrow- figure below) ⇒ Rep. gr. 24 ; Air filter; Removing and installing air filter housing

1. Clutch mechanism

33

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Pull clutch pedal pedal back to rest rest position. – Remove protective protective cap from from the bleeder bleeder valve -arrow-. -arrow-. – Connect brake brake filling and bleeding equipment equipment - VAS 5234- . – Connect bleeder bleeder hose to bleeder valve and to pressure pressure hose hose of fluid collector bottle. If necessary, use bleeder hose (670 mm long) - V.A.G 1238/B3for bleeding. – Switch on brake brake filling and bleeding equipmen equipmentt . •

Workin Working g pressu pressure: re: 2.0 2.0 bar, bar, posit positive ive pre pressu ssure re

– Open bleeder bleeder valve. – Allow about 100 100 cm3 of brake fluid to flow out. – Close bleeder bleeder valve. – Rapidly operate operate pedal pedal from stop to stop stop 10 to 15 times. times. – Open bleeder bleeder valve. – Allow another another 50 cm3 of brake fluid to flow out. – Close bleeder bleeder valve. – Switch off brake filling and bleeding bleeding equipment equipment and and relieve Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not pressure completely from bleeding equipment. permitted unless authorised 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.

– After finishing finishing air bleeding, bleeding, the clutch clutch pedal pedal must be activated activated several times.

Bleeder screw

4.5

Carry out Gui ded f aul t f i ndi ng using ⇒ Vehicle diagnostic tester before you renew the clutch master cylinder with an as‐ sumed fault.

– Push driver's driver's seat as far back back as possible. possible. – Unplug electrical connector -arrow- at clutch position sender G476- .

34

Rep. gr.30 - Clutch

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Unclip clutch position sender - G476G476- -item 2- at clutch master cylinder -1- -arrow- and remove.

Install in the reverse order of removal, observing the following: •

The latch -arrow-arrow- at at the clutch clutch positio position n sender sender - G476G476- must must be in good order.

•

The clutch clutch position position sender sender - G476G476- must must audibly audibly engage. engage.

•

Adapt Adapt clutch clutch posi positio tion n send sender er - G47 G4766- in in Gui ded f aul t f i ndi ng using ⇒ Vehicle diagnostic tester.


Protected by copyright. Copying for private or commercial purposes, 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.

♦ Grea Grease se for for clutch clutch plat plate e spline splines s ♦ For grea grease se allocat allocation, ion, refer refer to ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) . •

The The gear gearbo box x must must be be rem remov oved ed..

– Remove bolts bolts -arrows-. – Pull clutch release lever with release bearing and guide sleeve off input shaft and ball stud. Installation is carried out in the reverse order. – Installing gearbox gearbox ⇒ page 72 . 72 .

•

Guid Guide e sle sleev eve e to to gea gearb rbox ox ⇒ page 16

1. Clutch mechanism

35


– Remove clutch release lever lever together with release bearing and guide sleeve ⇒ page 35 . 35 . – Remove the guide guide sleeve -3- from the the clutch release release collar -2- by pressing upwards. – Rotate guide guide sleeve -3- approx. 90º 90º in -direction -direction of arrowagainst the clutch release bearing -2-, until the safety brackets of the guide sleeve matches with the recesses -4- in the re‐ lease bearing. – Pull guide sleeve sleeve out of release release bearing bearing in this position. position. Installation is carried out in the reverse order. – Install clutch release release lever with with release bearing bearing and and guide sleeve ⇒ page 35 . 35 .

– Remove clutch release lever lever together with release bearing and guide sleeve ⇒ page 35 . 35 . – Press locking locking lugs -arrows-arrows- together together on on reverse reverse side of of clutch release lever and remove release bearing -A- from clutch re‐ lease lever. – To install, press press release bearing bearing -A- into clutch release release lever until retaining hooks -arrows- engage. – Lubricate the the contact point point of the release release lever with the the ballhead pin with lubricant for the grooved clutch . – Install clutch release release lever with with release bearing bearing and and guide sleeve ⇒ page 35 . 35 .


36

Rep. gr.30 - Clutch


❑ Remo Removi ving ng and and ins insta tall llin ing g ⇒ Rep. gr. 13 ; Cylinder block (gearbox end); Assembly overview - fly‐ wheel . ❑ chec check k that that the the cent centri ring ng pins are correctly seat‐ ed ❑ Cont Contac actt surf surfac ace e for for clutch lining must be free of grooves, oil and grease ❑ Allo Alloca cati tion on ⇒ Elec Electr tron onic ic parts catalogue (ETKA) ❑ Cen Centra tralisi lisin ng ⇒ page 38 ❑ Remo Remove ve and and inst instal alll ⇒ page 38 ❑ Chec Checki king ng ends ends of dia‐ dia‐ phragm spring ⇒ page 40 ❑ Chec Check k spr sprin ing g con conne nec‐ c‐ tions and riveted con‐ nections ⇒ page 40 . 40 . ❑ Allo Alloca cati tion on ⇒ Elec Electr tron onic ic parts catalogue (ETKA) ❑ Loos Loosen en and and tig tight hten en in small steps diagonally diagonally ❑ M 6: 13 Nm ❑ M 7: 20 Nm Protected by copyright. Copying for private or commercial commercial purposes, in part or in whole, is not permitted unless authorised 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.

2. Clutch

37


♦ Coun Counte terh rhol old d - 3067 3067-♦ Centri Centring ng chuck chuck - 319 3190 0 AA♦ Torq Torque ue wren wrench ch V.A.G 1331♦ Grea Grease se for clutch clutch plate plate splines ♦ For For grease grease allo allocat cation ion,, refer refer to ⇒ Electronic parts cata‐ cata‐ logue (ETKA) .

•

Gearbox box rem removed ved.


38

Rep. gr.30 - Clutch

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Attach counterhold counterhold tool - 3067- before before loosening loosening bolts.

– Loosen all all bolts in small steps steps and diagonally. diagonally. – Remove clutch press and clutch clutch plate.

♦ Select correct clutch plate and pressure plate by checking en‐ gine code ⇒ Electronic parts catalogue (ETKA) ♦ Clean input shaft splines and, on used clutch plates, hub splines. Remove corrosion and apply only a very thin coat of clutch plate spline grease to splines. Then move the clutch plate on the input shaft from side to side, until the hub moves smoothly on the shaft. Eliminate excess grease. ♦ The pressure plates are greased and protected against cor‐ rosion. With the exception of the friction surface for the clutch plate, the clutch pressure plate must not be cleaned. Other‐ wise the working life of the clutch will be significantly reduced. ♦ The friction surface of the clutch pressure plate and the fly‐ wheel must be cleaned (degreased) thoroughly. ♦ If the clutch has burnt out, thoroughly clean the gearbox hous‐ ing in area of clutch and parts of the engine facing the gearbox in order to prevent odours. ♦ Clutch plate linings must make full contact with flywheel and friction surface of clutch pressure plate. Only then insert se‐ Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not curing permittedbolts. unless authorised 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.

♦ Tighten securing bolts in small steps diagonally in order not to damage centring holes of pressure plate and centring pins of flywheel . ♦ Check whether dowel sleeves for f or aligning engine and gearbox are fitted in cylinder block and install if necessary. ♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur. •

Installati Installation on locatio location n of clutch clutch plate: plate: labell labelling ing “gea “gearbox rbox end” end” or or spring cage is aligned to pressure plate.

2. Clutch

39


•

Wear to half half the thickn thickness ess of the diaphr diaphragm agm sprin spring g -arrows -arrows-- is permitted.

– Check spring connection between between pressure pressure plate and cover for cracks as well as rivet connections for secure seating. – If pressure plate plate has damaged damaged springs springs or loose rivet connec‐ tions -arrows-, it must be renewed.

I•

Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with Springs OK respect to the correctness of information in this document. Copyright by SEAT S.A.

Slight Slight kinking kinking on the the outside outside -arrows -arrows A- is norma normall on prod produc‐ uc‐ tion parts.

II - Extension spring damaged •

Renew Renew clutch clutch pressu pressure re plate plate ifif springs springs are broke broken n or badly badly bent -arrow B-.

– Check spring connections -arrows -arrows A- for for damage and make sure rivet fastenings -arrows B- are seated tightly. •

Renew Renew clutch clutch pressur pressure e plate plate if spring spring connectio connections ns are are broken broken or badly bent, or if riveting is loose.

– Check that riveting riveting -arrows -arrows B- is secure at at all springs -arrows A-. – Consecutively tighten tighten all bolts bolts to final setting in in clockwise di‐ rection. •

Renew Renew clutch clutch pressu pressure re plate plate ifif riveting riveting -arrow -arrow B- is loose. loose.

40

Rep. gr.30 - Clutch


– Check that sheet sheet metal ring in pressure plate -arrow-arrow- is not damaged. •

Renew Renew clutch clutch press pressure ure plate plate if metal metal ring is broken broken..

– To centre centre the clutch plate plate the adapter adapter - 3190 3190 A- must be be used. used. – Tighten all all bolts diagonally diagonally and in small small steps. – Installing gearbox gearbox ⇒ page 72 . 72 .

♦ Pressu Pressure re plat plate e on flyw flywhe heel el ⇒ page 37 Protected by copyright. Copying for private or commercial 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.

2. Clutch

41



42

Rep. gr.34 - Controls, housing


❑ Remo Remove ve befo before re remo remov‐ v‐ ing selector mechanism


1. Selector mechanism

43


♦ Disconnect battery before working on selector mechanism in engine compartment ⇒ Electrical Electrica l system; Rep. gr. 27 ; Battery; Disconnecting Disconnect ing and connecting battery . ♦ Removing and installing selector mechanism ⇒ page 46


44



❑ M 6, 8 Nm ❑ Sele Select ctor or hous housin ing g wit with h gear lever ❑ For For the the cent centre re cons consol ole e ❑ 1.5 Nm ❑ Asse Assemb mbly ly over overvi view ew ⇒ General body repairs, interior; Rep. gr. gr. 68 ; central console; assem‐ bly overview - central console. ❑ With gaiter ❑ Gear Gear knob knob and and gai gaite ter r cannot be separated from one another ❑ Alwa Always ys repl replac ace e toge togeth ther er ❑ Rem Remove and in install ⇒ page 47 ❑ To hold hold knob knob onto onto gear gear lever ❑ Must Must be rene renewe wed d ifif re‐ re‐ moved ❑ Secu Secure re to gear gear knob knob V.A.G 1275 A- using hose clip pliers



45


♦ Lubricate bearing positions and sliding surfaces. ♦ For grease allocation, refer to ⇒ Electronic parts catalogue (ETKA) .

❑ Repl Replac ace e afte afterr rem remov oval al ⇒ page 57

❑ Allo Alloca cati tion on ⇒ Elec Electr tron onic ic parts catalogue (ETKA) Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with ❑ Inst Instal alla lati tion on pos posit itio ion n respect to the correctness of information in this document. Copyright by SEAT S.A. ⇒ page 53 ❑ Afte Afterr inst instal alli ling ng,, adjus adjustt selector mechanism ⇒ page 55 ❑ Remo Remove ve and and inst instal alll ⇒ page 60 relay 60 relay lever together with cable endpiece ❑ To secu secure re sele select ctio ion n control cable to relay lever ❑ Afte Afterr inst instal alli ling ng,, adju adjus st selector mechanism ⇒ page 55 ❑ Do not not mix mix up. up. Cab Cable le end-pieces for gate se‐ lector cable to relay lev‐ er and gear selector ca‐ ble to gearbox selector lever are different. ❑ Allo Alloca cati tio on. ⇒ page 53 ❑ Remo Remove ve from from the the gat gate e relay lever ⇒ page 51 ❑ Pres Press s ont onto o rel relay ay leve lever r ⇒ page 52 ❑ ❑ ❑ ❑

Install Install so that that gap gap in spline splines s aligns aligns with selector selector shaft shaft ⇒ page 60 Grease before installing. installing. Inst Instal alla lati tion on posi positi tion on ⇒ page 53 After installing installing,, adjust adjust selec selector tor mecha mechanism nism ⇒ page 55

❑ Tightening torque ⇒ page 83 . 83 . ❑ To secure secure selection selection control control cable cable to to selectio selection n rod rod ❑ After installing installing,, adjust adjust selec selector tor mecha mechanism nism ⇒ page 55

46


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ❑ Do not mix up. Cable Cable end-pieces end-pieces for gate gate selector cable cable to relay lever lever and gear gear selector cable cable to gearbox gearbox selector lever are different. ❑ Allo Alloca cati tio on. ⇒ page 53 ❑ Must Must be rene renewed wed if remove removed d ❑ Conne Connect ct to to cabl cable e end end-p -piec iece. e. ❑ Inst Instal alla lati tion on pos posit itio ion n ⇒ page 42 ❑ Conne Connect ct to to cabl cable e end end-p -piec iece. e. ❑ Inst Instal alla lati tion on pos posit itio ion n ⇒ page 42 ❑ Inst Instal alla lati tion on pos posit itio ion n ⇒ page 45 ❑ ❑ ❑ ❑

Between Between gear gear lever lever casing casing and and vehicle vehicle underbo underbody dy Replace Replace after after remova removall of the selec selector tor housing housing Self Self--adhesive sive Stick Stick itit onto onto the the prot protect ective ive cover cover

❑ Must Must be rene renewed wed if remove removed d ❑ do not dama damage ge the gear gear selecto selectorr cables cables when when disassem disassemblin bling g ❑ Inst Instal alla lati tion on pos posit itio ion n ⇒ page 61 Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised 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.

❑ 3 Units ❑ for cable cable suppo support rt bracke brackett ❑ 20 Nm

❑ After installing installing,, adjust adjust selector selector mechanis mechanism m ⇒ page 55 ❑ 3 Units ❑ Cable Cable suppo support rt bracke brackett mountin mounting g on gearbox gearbox ❑ 3 Units


47

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ♦ Hose Hose clip clip pliers pliers - V.A.G V.A.G 1275 1275 A-

♦ Wedg Wedges es - T10 T1038 3833-


– Using removal removal wedge -T10383/1-T10383/1- , carefully pry gear gear lever boot off centre console insert -arrows-.

– Pull boot up and over gear gear knob. – Open clip -arrow-arrow- and and pull off gear gear knob together together with boot. boot.

Install in the reverse order of removal, observing the following: – Insert gear knob with the dust dust seal into the the gear level level all the way to the stop. – Attach gear knob knob with O-type O-type clip -arrow-arrow- (⇒ previous previous Fig.) to gear lever. Use hose clip pliers - V.A.G 1275 A- for this pur‐ pose.

48




– Disconnect vehicle vehicle battery battery ⇒ Electrical system; system; Rep. gr. gr. 27 ; Battery; Disconnecting and connecting battery . – Remove gear gear knob and and gaiter ⇒ page 47

– Remove the centre centre console ⇒ body installation tasks, interior; interior; Rep. gr. 68 ; centre console . – Remove the air channel channel for the rear rear foot area ⇒ Heating, Air conditioning; conditioning; Rep. gr. 87 ; Air line system; assembly overview overview - ventilation and distribution in the interior .

♦ It is very important to mark the position of the bolts for the upper support -2- before removing. ♦ If the bolts are not fitted in their original position, the centre console will not be correctly aligned.

– Mark installation position of the screws -1- to the bore bore holes in the top bracket -2-.



49

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Remove bolts bolts -1- and remove remove upper upper bracket -2-. -2-. – Remove nuts nuts -arrows- and and remove the holder -1- of the se‐ lector mechanism. – Remove the battery and bracket ⇒ Electrical system; Rep. gr. 27 .

– Remove circlip -1- for gear gear selector cable cable -2- from from gearbox gearbox selector lever -3-. – Pull gear selector selector cable -2-2- off pin. – Remove gate gate relay lever lever -4- together with with gate selector selector cable end-piece ⇒ page 60 . 60 . Protected by copyright. Copying for private or commercial 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.

– Pull locking locking mechanism mechanism forwards in direction direction of of -arrow -arrow 1- onto stop and then turn to left in direction of -arrow 2- to lock. – Then push push gate relay relay lever forwards forwards and and thread gate selector selector cable out of cable end-piece.

50



– Pull off clip -arrow -arrow 1- and remove remove relay relay lever lever together together with ca‐ ble end-piece -arrow 2-.

– Remove cable cable support bracket bracket from gearbox gearbox -arrows-. -arrows-.

– Install thermal thermal shield for the the middle tunnel tunnel ⇒ General body body repairs, exterior; exterior; Rep. gr. 66 ; Covers / Decorative trim trim / Pipe expander / Covers; Assembly overview - heat shield . Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised 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.

Observe the installation position of the gear selector cables in the selector mechanism and in the gearbox console. – Swing down selector housing housing and remove remove together together with con‐ trol cables.

– Insert a flat-blade screwdriver -A- between between bush bush -B-B- and relay lever.



51


•

Rela Relay y leve leverr has has bee been n rem remov oved ed

•

Grea Grease se supp suppor ortt pins pins for cable cable end end-pi -piece ece..

•

For grease grease allocatio allocation, n, refer refer to ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) .

•

Press Press on cable cable end-p end-piece iece only at bush bush -arrow-arrow-..

•

Cable Cable end-p end-piece iece must move freely freely on on relay relay lever. lever.

•

Cable Cable end end-pi -piece ece must must be be behi behind nd catc catch. h.

•

Ensur Ensure e that that compo compone nents nts enga engage ge secur securely ely..

– Align selector housing parallel parallel to body. body. •

Distance Distance to body body must then be the the same same on on both both sides. sides.

Bolt gear stick housing – Route cables cables -1- from selector selector mechanism mechanism -2- to gearbox gearbox as follows: •

Cables Cables must must lie paralle parallell to each each other other and must must not not cross. cross.

•

The cable cpermitted ables s unless must mustauthorised be route routed d in S.A. the theSEAT slot slotS.A provid prdoes ovided ed in heat hea shield shieany ld liability with by SEAT not guarantee ortaccept respect to the correctness of information in this document. Copyright by SEAT S.A. -3-.

Protected by copyright. Copying for private or commercial commercial purposes, in part or in whole, is not

The enlargement shows the heat shield from above.

Clip -A- holds cables and heat shield together in position. The holes on the cable securing elements have different diame‐ ters.

52



The holes on the cable securing elements have different diame‐ ters.

1. - Gear selector cable to gearbox selector lev‐ er

8.5 mm

2. - Gate selector cable to relay lever

10 mm

1 - Gear selection rod 2 - Relay lever engages in guide rail of gearbox selector lever via shoe -arrow-.


•

When installin installing, g, grease grease followi following ng areas areas particu particularl larly y carefully carefully..

•

Shaft Shaft -A-A- of of gate gate rela relay y lever lever -arro -arrowsws-..

•

Guide Guide rail rail -B- of of gearbox gearbox selecto selectorr lever lever into which which gate gate relay relay lever engages

•

Suppo Support rt pin for cable cable end-p end-piec iece e

•


•

The relay relay lever lever and and gearb gearbox ox selecto selectorr lever lever may look look differe different nt from the original part.


53


– When fitting the the gearbox gearbox selector lever, lever, ensure that that the gap -arrow A- is aligned with the master spline -arrow B-. – Secure gear gear selector cable cable with new securing securing clip to gearbox selector lever.

Lubricate bearing positions and sliding surfaces. For grease al‐ location, refer to ⇒ Electronic parts catalogue (ETKA) . – Insert relay lever lever together together with cable end-piece end-piece -arrow -arrow 2- into into selector mechanism cover as far as stop. – Press on clip -arrow -arrow 1-, making making sure itit engages securely. securely. – Insert the selector selector cable in the fastening element. – Install damping damping into selector selector housing ⇒ General General body body repairs, repairs, interior; Rep. gr. gr. 68 . – Install centre console console ⇒ General body repairs, repairs, interior; Rep. Rep. gr. 68 ; central console; assembly assembly overview - central console console .

– Renew clamp -arrow-. Adjust selector selector mechanism ⇒ page 55 . 55 . – Install gaiter with with selector knob knob ⇒ page 47 . 47 . – Install thermal thermal shield for the the middle tunnel tunnel ⇒ General body body repairs, exterior; Rep. gr. 66 ; Floor covering; assembly over‐ view - floor covering . – Assemble exhaust exhaust system ⇒ Rep. gr. 26 ; Exhaust pipes/ pipes/ silencers; Assembly overview - silencer . – Install battery tray tray if installed ⇒ Electrical system; system; Rep. gr. 27 ; Battery; Removing and installing battery tray . – Connect vehicle vehicle battery ⇒ Electrical system; system; Rep. gr. 27 ; purposes, in part or in whole, is not Battery; Disconnecting and connectingProtected batteryby.copyright. Copying for private or commercial purposes,


♦ Select Selector or hou housin sing g to bod body y ⇒ page 45 ♦ Selector Selector cable cable support support bracke brackett to gearbo gearbox x ⇒ page 46

54



♦ Locki Locking ng bolt bolt - T1002 T10027 7 AA-

•

Drive Drive and transmis transmission sion eleme elements nts of the the gear gear drive drive mecha mechanism nism in perfect condition.

•

Selec Selector tor mecha mechanis nism m must must move move free freely. ly.

•

Gearbo Gearbox, x, clutch clutch and and clutch clutch mecha mechanism nism in perfect perfect condition condition..

•

Gear Gearbo box x in in neut neutra ral. l.


– Remove complete complete air filter filter housing if angled angled rod for securing selector shaft and securing mechanism for gear selector cable and gate selector cable are not accessible ⇒ Rep. gr. 24 ; Air filter; Removing and installing air filter housing . – Pull locking mechanisms mechanisms on on gate selector selector cable and gear se‐ lector cable end-pieces forward to stop -direction of arrow 1and then turn to left to lock -direction of arrow 2-.

Lock selector shaft as follows: – Press selector selector shaft down in -direction of of arrow 1-. – While pressing pressing down selector selector shaft, turn angled rod rod -A- in -direction of arrow 2- and at the same time press it in until it engages in selector shaft.


55

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Using removal removal wedge -T10383/1-T10383/1- , carefully pry gear gear lever boot off centre console insert -arrows-.

– Pull boot up and over gear gear knob.

-Arrow- can be disregarded.

Now secure gear lever as follows: – Move gear lever to neutral neutral position and, if necessary, necessary, keep pressing the gear lever to the left. – Guide locking locking pin - T10027 T10027 A- through through the damping damping -A-, -A-, hole -B- into hole -C-.

– Gate and selector cables -B- must be inserted, free of tension, tension, into locking mechanisms -A-.

Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with gear selector cable and gate respect to the correctness of information in this document. Copyright by SEAT S.A.

– Now turn locking mechanisms mechanisms on on selector cable end pieces clockwise to stop -direction of arrow 1-.

The spring presses the locking mechanism into normal position in direction of -arrow 2-.

56


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Turn angle angle lever -A- back to the initial initial position -in direction of arrow-. •

During During this this proced procedure ure,, locking locking pin pin -A-A- must must be press pressed ed out out of gearbox in -direction of arrow-.

– Pull locking pin pin out of damping damping -A- and and holes -B- and -C-. – Install gaiter with selector knob knob ⇒ page 47 . 47 . – Ensure that that the selector shaft shaft can move freely. freely. – If removed, install install complete air filter housing housing ⇒ Rep. gr. 24 ; Air filter; Removing Removing and installing installing air filter filter housing .

•

With gearb gearbox ox in neutr neutral, al, select selector or lever lever must must be in selecto selectorr lever lever gate for 3rd and 4th gear.

– Engage clutch. clutch. – Select all the gears gears several several times. Pay particular particular attention attention to the operation of the reverse gear locking mechanism. – If it continues to be difficult to engage engage a gear gear after repeated repeated attempts, repeat adjustment procedure of selector mechanism ⇒ page 55 . 55 .

♦ Tube Tube eleme element nt - VW VW 423 423--



57

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ♦ Torqu Torque e wren wrench ch - V.A. V.A.G G 1331 1331--

♦ Seal Sealin ing g grea grease se ♦ For grea grease se allocat allocation, ion, refer refer to ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) . – Remove gearbox gearbox selector selector lever ⇒ page 60 and 60 and gate relay lever ⇒ page 60 . 60 . – Lever seal out out using a screwdriver. screwdriver. – Lightly oil outer outer circumference circumference of new oil oil seal. – Fill space space between between sealing lip and and dust dust lip -arrow- with sealing sealing grease .

– Install gearbox gearbox selector lever lever ⇒ page 60 and 60 and gate relay lever ⇒ page 60 . 60 .


58



The holes on the cable securing elements have different diame‐ ters.

-1-1- Gea Gearr sel selec ecto torr cabl cable e to gear gearbo box x sele select ctor or leve leverr

8.5 8.5 mm

-2- Gate selector cable to relay lever

10 mm

1 - Gear selection rod 2 - Relay lever engages in guide rail of gearbox selector lever via shoe -arrow-.


•

When installin installing, g, grease grease followi following ng areas areas particu particularl larly y carefully carefully..

•

Shaft Shaft -A-A- of of gate gate rela relay y lever lever -arro -arrowsws-..

•

Guide Guide rail rail -B- of of gearbox gearbox selecto selectorr lever lever into which which gate gate relay relay lever engages

•

Pin for moun mountin ting g cabl cable-e e-end nd piece. piece.

•


•

The relay relay lever lever and and gearb gearbox ox selecto selectorr lever lever may look look differe different nt from the original part.


59


– When fitting the the gearbox gearbox selector lever, lever, ensure that that the gap -arrow A- is aligned with the master spline -arrow B-.

– Pull locking locking mechanism mechanism forwards in direction direction of of -arrow -arrow 1- onto stop and then turn to left in direction of -arrow 2- to lock.

– Then push relay lever forwards forwards (-direction (-direction of arrow arrow 3-). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Pull off clip -arrow -arrow 1- and remove remove relay relay lever lever together togeth er withauthorise ca‐ d by SEAT S.A. SEAT S.A does not guarantee or accept any liability with permitted unless authorised ble end-piece. respect to the correctness of information in this document. Copyright by SEAT S.A.

Cable end-piece must be located behind catch -arrow 2-. •

It is only only permi permissibl ssible e to remo remove ve cable cable end-p end-piece iece after after relay relay lever has been removed ⇒ page 51 . 51 .

– Press cable end-piece end-piece onto onto relay lever lever ⇒ page 52 . 52 . – Insert gate relay relay lever with cable end-piece end-piece as far as as stop. •

Clip Clip -arr -arrow ow 11- secur secures es the the rela relay y lever lever..

•

Ensur Ensure e prop proper er engag engagem emen entt of clip. clip.

•

Cable Cable end-pi end-piece ece must must be be located located behind behind catch catch -arrow -arrow 2- (⇒ previous figure).

60



•

Rela Relay y leve leverr has has been been remo remove ved d

– Insert a flat-blade screwdriver -A- between between bush bush -B-B- and relay lever.

•

Rela Relay y leve leverr has has been been remo remove ved d

•

Grea Grease se pin pin for for cab cable le end end-p -pie iece ce

•


•

Press Press on cable cable end-p end-piece iece only at bush bush -arrow-. -arrow-.

•

Cable Cable endend-piec piece e must must move move freely freely on on relay relay lever. lever.

•

It must must be loca located ted beh behind ind catch catch -arr -arrow ow 22- ⇒ page 60 . 60 .



61


1

M12×60

2

80

2

M12×165 ♦ Addition Additionally, ally, start‐ start‐ er to gearbox

2

80

3

M 10 x 55

3

40

4

M12×70

2

80

Item -A- dowel sleeves for centring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised 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.

♦ Supp Suppor ort. t. - 10 10 - 222 222 AA♦ Shackl Shackle e - 10 - 222 222 A /12/12♦ Adapte Adapterr for for the engin engine e bracket. - 10 222A/18♦ Squar Square e pipe pipe - T40 T40091 091/1/1and connector - T40091/3♦ Spindl Spindle e from from engine engine sup‐ sup‐ port supplement set T40093 /3-

62


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ♦ Temp Templa late te - 328 3282/ 2/46 46-♦ Suppo Support rt elem element ents s for gear‐ gear‐ box (determine when set‐ ting adjustment plate on gearbox support ) ♦ Torq Torque ue wren wrench ch V.A.G 1331♦ Torq Torque ue wren wrench ch V.A.G 1332♦ Engin Engine/g e/gea earb rbox ox eleva elevator tor V.A.G 1383 A-


2. Gearbox : removing and fitting

63


♦ Adapte Adapterr - 10-2 10-222A 22A/16 /16-♦ Bar - 2024 A / 1- from lifting lifting tackle tackle - 2024A2024A♦ Suppo Support rt bra bracke ckett - T103 T10346 46-♦ or bracke brackett - T1034 T10346/1 6/1-♦ Hexag Hexagon on head head bolt bolt M10 M10 x 20 20 ♦ Continue Continued d for all vehicle vehicles, s, clutch plate plate spline spline grease grease ♦ For grea grease se allocat allocation, ion, refer refer to ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) .

– Remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery tray . – Loosen the brackets -arrow-arrow- for the air duct hose. hose. – Separate air air intake hose hose -2- from air air filter housing housing -1-. – Carefully disconnect the air filter housing -1- from the retaining bolts in an upward motion, sequentially. – Disconnect the air filter housing housing -1- with the air duct hoses. hoses.


– Remove securing securing clip -arrow -arrow 1- for gear gear selector cable from gearbox selector lever -B-. – Remove the relay relay lever -A-A- together with cable end-piece end-piece ⇒ page 60 . 60 . – Remove gearbox gearbox selector selector lever -B- after after removing removing the nut -arrow 2- .

64


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Unscrew bolts -arrows- and place cable support bracket to one side together with cables.

– Unscrew bolts bolts -arrows-arrows- and place clutch slave cylinder cylinder to one one side. Do not open pipes.


– Then remove remove upper securing bolt bolt on starter. – Remove the upper screws screws -2 and 3- of top engine/gearbo engine/gearbox. x. – Then, if required, required, remove remove the hoses hoses and lines in the area of of the lifting eyes of the engine to secure the gearbox support 10 - 222 A- . – Install support support bracket - 10-222 10-222 A- as as follows: Required special tools, workshop equipment and auxiliary items: ♦ Adapt Adapter er - 10 - 222 222 A /18/18♦ 2 shackles shackles - 10 - 222 222 A /12- (requ (required ired when when spindl spindles es of engine engine support bracket cannot be engaged in lifting eyes of engine) ♦ 2 Adap Adapter ter - 10 - 222 222 A /29/29♦ 2 Squa Square re tube tubes s - T400 T40091 91/1/1♦ 2 Attach Attachmen mentt elemen elements ts - T40091/3 T40091/3-♦ 2 Spi Spindl ndles es - T40 T40093 093 /3♦ 2 Adap Adapter ter - T400 T40093/ 93/3 3 6A6A – On both sides of vehicle, vehicle, insert adapters - 10 - 222 222 A /29- be‐ tween upper wheel housing longitudinal member and mount‐ ing plate for wing located underneath. ♦ Instal Installat lation ion posit position ion::

Arrow -2- points points in direction direction of travel.


65

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Fit support support bracket bracket - 10-222 10-222 A- with adapters - 10 - 222 A /29right behind mounting plate -arrow- onto carrier.

•

Fit adapt adapter er - 10 10 - 222 222 A /29/29- as as close close as possib possible le to the outer outer edge -arrows- which faces towards the wing.


– Bolt bracket - T10346T10346- or -T10346/1-T10346/1- to rear left mounting hole for battery tray. – To do this, use a collar bolt bolt M 6 x 80 or a securing securing bolt bolt for battery tray. – Attach bar - 2024 2024 A / 1- from from lifting tackle - 2024 A- at top top to shackle - 10-222A/16- on adapter - 10 - 222 A /12- , and secure it at bottom to bracket - T10346/1- using a cotter pin -arrow-.

66


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Hook the spindle spindle using the the shackle - 10 - 222 A /12- into the eyelets. – Slightly take up up weight of engine/gear engine/gearbox box assembly assembly on the spindles of the carrier - 10 222A- . – Remove noise noise insulation components components ⇒ General body body re‐ pairs, exterior; exterior; Rep. gr. 66 ; Noise insulation insulation . – Remove the lower part of of the front left wheel wheel housing housing liner ⇒ body installation installation tasks, exterior; Rep. gr. gr. 66 ; wheel housing liner; Assembly overview - front wheel housing liner .

– Remove nut nut -arrow- and and remove retainer for for electrical lines. lines. – Remove starter starter ⇒ Electrical system; system; Rep. gr. 27 ; Starter . Protected by copyright. Copying for private or commercial purposes, 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.

– If fitted, unscrew front left vehicle level sender sender - G78- from from transverse link ⇒ Running gear, axles, steering; Rep. gr. 43 ; Vehicle level sender; Assembly overview - f ront vehicle level sender .

– Pull connector connector -1- off oil level level and oil temperatur temperature e sender G266- .


67

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Unplug electrical electrical connectors: connectors: 1-

Reve Revers rsin ing g lig light ht swit switch ch - F4F4-

2-

Gearb Gearbox ox neu neutra trall posit position ion sende senderr - G70 G7011-

– Remove bolts bolts -arrows- for for exhaust pipe pipe bracket from from sub‐ frame.

– Disconnect exhaust exhaust system at clamp clamp -arrow-. -arrow-.


– Remove pendulum pendulum support. support. – Remove left coupling coupling rod rod of anti-roll anti-roll bar and and place to one side ⇒ Running gear, axles, steering; Rep. gr. 42 ; Removing and installing anti-roll bar, coupling rod .

68


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – If required, required, remove drive shaft heat shield -Arrows- ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; remove and install drive shaft heat shield . – Remove drive drive shafts from flange flange shafts and and tie them up as high as possible, do not damage surface protection ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; removing and installing drive shaft .

– Remove nut nut -arrow- and and detach earth earth wire.

– Remove hexagon bolts -arrows- at left mounting from gearbox mounting.

– Lower gearbox gearbox distance distance -a- by adjusting adjusting spindles spindles of support support bracket - 10 - 222 A- . •

Meas Measur urem emen entt -a-a- =60 =60 mm. mm.



69

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Removing gearbox gearbox support: support: •

The bolts bolts -arro -arrows ws 1- for the the gearb gearbox ox mounti mounting ng are are screwe screwed d out.

– Unscrew the screws -arrows -arrows 2- and remove remove the gearbox sup‐ port.

– Unscrew bolts - 7, 8- of the connection connection between between gearbox gearbox and engine. – Bolts -1, 6, 99- securing securing gearbox gearbox to engine engine are are unscrewed unscrewed at a later stage.

To remove gearbox “0AJ” set up gearbox support - 3282- with adjustment plate - 3282/46- . – Insert gearbox gearbox support support - 3282- in engine and and gearbox gearbox jack . – Place adjustment adjustment plate - 3282/46- on gearbox support - 3282- . •

The adjus adjustmen tmentt plate plate can only be fitted fitted in one one positio position. n.

– Align arms of of gearbox support support according according to holes holes in adjust‐ ment plate – Secure support support elements elements as illustrated illustrated on adjustment adjustment plate. •

The arro arrow w symbol symbol on the adjus adjustmen tmentt plate plate points points in the direc‐ direc‐ tion of travel. Align adjustment plate parallel with gearbox.

– Secure bolts bolts - 3282/453282/45- -arrow- to gearbox using using a M 8 nut. nut. The bolts - 3282/45- should be flush below with the guide from the gearbox support - 3282- .


70


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Screw pin - 3282/293282/29- into rear hole for bolt bolt securing securing pendulum support to gearbox. – Remove engine/gear engine/gearbox box connecting connecting bolt -arrow-. -arrow-.

– Remove engine/gear engine/gearbox box connecting connecting bolt -A- . – Remove the remaining bolts connecting connecting the engine engine to the gearbox.

– Press gearbox gearbox out of dowel dowel sleeves and and carefully swing swing to‐ wards front end. – Carefully guide guide gearbox gearbox with right-hand right-hand flange flange shaft -A- past past flywheel/intermediate flywheel/intermediate plate.

– Turn gearbox in the area of the differential upwards and in in the area of the 5th/6th gear downwards. – Lower gearbox, gearbox, paying paying attention to the clearance clearance of flange shaft -A- to flywheel and flange shaft -B- to subframe. – If necessary, carefully carefully push engine engine towards towards front (2nd (2nd me‐ chanic required). – On lowering lowering it, modify the position position of the gearbox using using the spindles of the gearbox support unit - 3282- .

Pay attention to all pipes/hoses/wiring when lowering gearbox. 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.


71


Refer to procedure “Removing gearbox” for required special to ols ⇒ page 62 . . – All threaded threaded holes into which which self-locking self-locking bolts are to be screwed must be carefully cleaned of residual locking fluid us‐ ing a thread chaser. – Renew self-locking self-locking nuts and and bolts after each each removal. removal. – Check whether whether dowel sleeves sleeves for centring centring engine/gearbox engine/gearbox have been fitted in cylinder block, install if necessary. If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noisesProtected from by the gearbox (rattling gears purposes, in part or in whole, is not copyright. Copying for privateof or commercial permitted unless authorised authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with which are not engaged) could occur. respect to the correctness of information in this document. Copyright by SEAT S.A.

– Make sure that that intermediate intermediate plate is engaged engaged on on sealing flange -top arrow- and fitted onto dowel sleeves -bottom arrows-. – Clean splines of input input shaft and apply a thin coat coat of grease for clutch plate splines . It must be possible to move the clutch plate from side to side on the input shaft.

– Insert gearbox gearbox support support - 3282- in engine and and gearbox gearbox jack . Gearbox support - 3282- is aligned with adjustment plate 3282/46- for installation of gearbox. – Fit adjustment adjustment plate - 3282/463282/46- on gearbox gearbox support support - 32823282(adjustment plate fits in only one position). – Align arms of of gearbox support support - 32823282- according according to holes in in adjustment plate - 3282/46- . – Screw mounts mounts into adjustment adjustment plate - 3282/463282/46- as illustrated. illustrated. – Place gearbox gearbox on engine engine and gearbox gearbox jack . – Align adjustment adjustment plate plate - 3282/463282/46- and and gearbox gearbox parallel parallel to one one another. – Screw pin - 3282/293282/29- into into rear hole hole on gearbox gearbox for securing securing bolt of pendulum support.

72


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Secure bolts bolts - 3282/453282/45- -arrow- to gearbox gearbox using a M 8 nut. nut. The bolts - 3282/45- should be flush below with the guide from the gearbox support - 3282- . – Turn gearbox in the area of the differential upwards and in in the area of the 5th/6th gear downwards. – Position engine and gearbox jack under under the vehicle; vehicle; arrow the adjustment plate points in the direction of travel of the vehicle. – Raise gearbox gearbox carefully. carefully. •

6th gear gear cover cover of gear gearbo box x faces faces fron frontt end. end.

Be careful of all lines when installing gearbox. – Carefully push push the engine engine forwards forwards with the the assistance of an‐ other mechanic. – Then carefully carefully guide gearbox gearbox and and left-hand flange shaft -B-Bpast subframe and guide right-hand flange shaft -A- past clutch pressure plate.

– Carefully guide guide gearbox gearbox with right-hand right-hand flange flange shaft -A- past past flywheel, as shown. – Align gearbox gearbox in installation installation position to engine. Protected by copyright. Copying for private or commercial commercial purposes, in part or in whole, is not permitted unless authorised 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.

– Position engine and gearbox jack under under the vehicle; vehicle; arrow the adjustment plate points in the direction of travel of the vehicle. – Lower gearbox gearbox in area area of differential differential to stop in -direction of arrow- (different gearbox shown in illustration). – Raise gearbox gearbox carefully. carefully. – Carefully push push the engine engine forwards forwards with the the assistance of an‐ other mechanic.


73

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – While doing so, guide guide gearbox gearbox with flange flange shaft shaft past flywheel, dowel sleeve -arrow 2- and, if necessary, past subframe -arrow 1-. – Be aware of of coolant hose -1- and starter starter mounting mounting -2- when when guiding gearbox past subframe -3- (⇒ previous illustration).

– Guide left flange flange shaft -B- past subframe subframe bracket -arrow-. -arrow-. – When raising raising gearbox, gearbox, change position position of gearbox gearbox as neces‐ neces‐ sary using spindles of gearbox support - 3282- .

Be careful of all lines when raising the gearbox. – Align gearbox gearbox in installation installation position to engine.

– Install gearbox, gearbox, screw and tighten bolts above above and below below -arrow- of right-hand flange shaft ⇒ page 62 . 62 . – Screw and tighten tighten the remaining remaining bolts bolts connecting gearbox to engine ⇒ page 62 . 62 . – After gearbox gearbox has been been bolted to engine, engine, remove remove engine and gearbox jack from gearbox.


74


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Install gearbox gearbox support support with new bolts -arrows -arrows 2⇒ page 79 . 79 . – Align engine/gearb engine/gearbox ox assembly in installation installation position; position; to do so, tighten spindles of support bracket - 10 - 222 A- until gear‐ box support makes contact with gearbox mounting.

– Screw in new bolts and tighten tighten them -arrows -arrows 1- ⇒ page 79 . 79 .

Install engine and gearbox mounting free of tension ⇒ Rep. gr. 10 ; Removing and installing engine; Installing engine . – Install earth wire -arrow-. -arrow-. – Do not remove remove support support bracket - 10 - 222 A- until all bolts se‐ curing the assembly mounting have been tightened to speci‐ fied torque! – Screw in upper upper engine/gearbo engine/gearbox x securing bolts bolts and tighten them ⇒ page 62 . 62 . Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised 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.

– Install pendulum pendulum support support with new bolts bolts ⇒ Rep. gr. 10 ; As‐ sembly mountings; Assembly overview - assembly mount‐ ings . – Check the settings settings of the mechanical mechanical components components ⇒ Rep. gr. 10 ; all mechanical mechanical brackets; Check mechanical brackets . – Assemble exhaust exhaust system ⇒ Rep. gr. 26 ; Emission control; Assembly overview overview – emission control .


75

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Install drive shafts shafts ⇒ Running gear, gear, axles, steering; steering; Rep. gr. gr. 40 ; Drive shaft; Removing and installing drive shafts . – Install heat shield for drive shaft, if present -arrows- ⇒ chassis, axles, steering; steering; Rep. gr. 40 ; Drive shaft; heat shield remove remove and re-install drive shaft .

– If present screw screw the indicator indicator for the the front vehicle vehicle level - G78to the crossbeam ⇒ Running gear, axles, steering; Rep. gr. 43 ; Indicator of vehicle level; installing and removing the in‐ dicator for front vehicle level G78/G289 . – Install coupling coupling rod ⇒ Running gear, axles, steering; steering; Rep. Rep. gr. 40 .

– Attach connector connector -1- to oil oil level and oil temperature temperature sender G266- . – Ensure the braking system vacuum hose hose is positioned cor‐ rectly. If necessary, install the hose hose ⇒ Brake system; Rep. gr. gr. 47 ; Servo brake / main brake cylinder; Assembly Overview servo brake / main brake cylinder .

– Install starter and and attach bracket bracket for electrical electrical wiring -Arrow-Arrow⇒ Electrical system; Rep. Rep. gr. gr. 27 ; Starter . – Install clutch slave cylinder ⇒ page 28 . 28 .


76


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Gearboxes Gearboxes for vehicles with with start-stop system: system: join connector connector -arrow- to gearbox neutral position sender - G701- .

– Install cable support support bracket bracket on gearbox gearbox and tighten tighten bolts -arrows- ⇒ page 46 . 46 .



77

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Install gearbox gearbox selector lever lever -B- ⇒ page 60 . 60 . – Tighten hexagon hexagon nut -arrow -arrow 2-. ⇒ page 46 – Install relay lever lever -A- together together with cable cable end-piece end-piece ⇒ page 60 . 60 . – Spread a small small amount amount of grease on on pin of gearbox gearbox selector selector lever -B-. Allocate grease for selector selector mechanism mechanism using using ⇒ Electronic parts catalogue (ETKA) . – Attach gear selector selector cable to gearbox gearbox selector lever. lever. – Renew securing securing clip -arrow -arrow 1- each time after removing. removing. – Adjust selector mechanism ⇒ page 55 . 55 . – Install battery battery tray, battery and and battery battery cover ⇒ Electrical sys‐ tem; Rep. gr. 27 ; Battery; Removing and and installing battery battery . – Install engine engine cover and air filter ⇒ Rep. gr. 24 ; Air filter; Removing and installing air filter housing . – Check the position position of the filler neck of the screen screen wash water water container ⇒ Electrical system; Rep. Rep . gr. 92 ; Windscreen Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not washing system; Assembly overview - windscreen washing permitted unless authorised authoris ed 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. system . – Remove the lower lower part of of the front left wheel wheel housing liner ⇒ body installation installation tasks, exterior; Rep. gr. gr. 66 ; wheel housing housing liner; Assembly overview - front wheel housing liner . – Check the gear gear oil ⇒ page 118 . 118 . – Install the lower lower part of the front front left wheel wheel housing liner liner ⇒ body installation installation tasks, exterior; Rep. gr. gr. 66 ; wheel housing housing liner; Assembly overview - front wheel housing liner . – Remove the noise noise silencer silencer ⇒ chassis installation installation work, exte‐ rior; Rep. gr. 66 ; Noise silencer; silencer; installation overview overview - noise silencer . – If the vehicle has an indicator for the front vehicle level - G78- , the headlight adjustment must be checked ⇒ Running gear, axles, steering; Rep. gr. 43 ; Vehicle level indicator; Assembly Assembly overview - Indicator Indicator for front vehicle level level ⇒ electrical system; system; Rep. gr. 94 . – If the surface surface protection protection has been been damaged, damaged, a repair must must be undertaken with materials prescribed by the manufacturer ⇒ Paintwork guidelines .

78



❑ ⇒ Rep. Rep. gr. gr. 10 ; Asse Assem‐ m‐ bly mountings; Assem‐ bly overview - assembly mountings ❑ ⇒ Rep. Rep. gr. gr. 10 ; Asse Assem‐ m‐ bly mountings; Assem‐ bly overview - assembly mountings ❑ ⇒ Rep. Rep. gr. gr. 10 ; Asse Assem‐ m‐ bly mountings; Assem‐ bly overview - assembly mountings ❑ ⇒ Rep. Rep. gr. gr. 10 ; Asse Assem‐ m‐ bly mountings; Assem‐ bly overview - assembly mountings ❑ ⇒ Rep. Rep. gr. gr. 10 ; Asse Assem‐ m‐ bly mountings; Assem‐ bly overview - assembly mountings ❑ ⇒ Rep. Rep. gr. gr. 10 ; Asse Assem‐ m‐ Protected by copyright. Copying for private or commercial commercial purposes, in part or in whole, is not bly mountings; Assem‐ permitted unless authorised authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with bly overview assembly respect to-the correctness of information in this document. Copyright by SEAT S.A. mountings

❑ ⇒ Rep. Rep. gr. gr. 10 ; Asse Assem‐ m‐ bly mountings; Assem‐ bly overview - assembly mountings ❑ ⇒ Rep. gr. 10 ; Assembly Assembly mountings; mountings; Assembly Assembly overview - assembly mountings or ⇒ Running gear, axles, steering; Rep. Rep. gr. 40 ; Subframe; Assembly Assembly overview - subframe subframe ❑ ⇒ Rep. gr. 10 ; Assembly Assembly moun mounting tings; s; Assemb Assembly ly overvi overview ew - assembly assembly mounting mountings s or ⇒ Running gear, axles, steering; Rep. gr. 40 ; Mechanics bearing saddle; assembly overview - mechanics bearing saddle

❑ ⇒ Rep. gr. 10 ; Assembly Assembly mountings; mountings; Assembly Assembly overview - assembly mountings or ⇒ Running gear, axles, steering; Rep. Rep. gr. 40 ; Subframe; Assembly Assembly overview - subframe subframe ❑ ⇒ Rep. gr. 10 ; Assembly Assembly mountings; mountings; Assembly Assembly overview - assembly mountings or ⇒ Running gear, axles, steering; Rep. Rep. gr. 40 ; Subframe; Assembly Assembly overview - subframe subframe

3. Engine/gearbox mountings

79


❑ Must Must be be ren renewe ewed d ifif rem remove oved d ❑ 60 Nm + +90° ❑ Must Must be be ren renewe ewed d ifif rem remove oved d ❑ 60 Nm + +90° ❑ ⇒ Rep. gr. 10 ; Assembly Assembly mountin mountings; gs; Assem Assembly bly overv overview iew - assembly assembly mounting mountings s ❑ ⇒ Rep. gr. 10 ; Assembly Assembly mountin mountings; gs; Assem Assembly bly overv overview iew - assembly assembly mounting mountings s

❑ Must Must be be ren renewe ewed d ifif rem remove oved d ❑ 3 Units ❑ 40 Nm + +90°


80



♦ Gear Gearbo box x lifting lifting tack tackle le - 3336 3336--


– Bolt gearbox gearbox lifting tackle - 3336- to clutch clutch housing.

– Adjust support support beam on sliding piece using locking pin -arrow-. No. of holes visible = 5 – Lift gearbox gearbox using using workshop workshop crane crane and and gearbox gearbox lifting tackle 3336- . – Set down gearbox gearbox as required required (for (for example in in transport transport con‐ tainer).

4. Transport of gearbox

81


❑ (Gea (Gearr cha chang nge e pro prong ngs) s)


82




♦ Lubricate bearing positions and sliding surfaces. ♦ For grease allocation, refer to ⇒ Electronic parts catalogue (ETKA) .

5. Gearbox: disassembly and assembly

83


❑ For For the the gear gear sele select ctio ion n shaft ❑ Press ou out ⇒ page 110 ❑ Press on on ⇒ page 110 ❑ Rene Renew w toge togeth ther er ❑ For For adju adjust stin ing g sele select ctor or mechanism ❑ Removal ⇒ page 110 ❑ Press on on ⇒ page 110 ❑ Inst Instal alla lati tion on pos posit itio ion n ⇒ page 53

❑ Repl Replac ace e afte afterr rem remov oval al ⇒ page 57 ❑ For For gea gearb rbox ox brea breath ther er ❑ Posi Positi tion on so that that the the teeth free area is inser‐ ted on the selector shaft ❑ Can Can be be rep repla lace ced d wit with h the gearbox gearbox drive mech‐ mech‐ anism in place ❑ Inst Instal alla lati tion on pos posit itio ion n ⇒ page 53 ❑ Self Self--lock lockin ing g ❑ Must Must be be ren renewe ewed d ifif rem remove oved d ❑ 23 Nm


84



❑ Dism Disman antl tlin ing g and and ass assem em‐‐ bling ⇒ page 146 . 146 . ❑ Repairing ⇒ page 111 . 111 . ❑ Tigh Tighte teni ning ng tor torqu que e ⇒ page 119

❑ Remo Remove ve and and inst instal alll ⇒ page 88 ❑ Asse Assemb mbli ling ng,, fro from m ⇒ page 146 ❑ Remo Remove ve and and inst instal alll ⇒ page 146 ❑ Self Self--lock lockiing ❑ Must Must be rene renewe wed d ifif re‐ re‐ moved ❑ For For sec secur urin ing g bea beari ring ng support for input and output shafts ⇒ page 85 . 85 . ❑ Tigh Tighte ten n wit with h 5 Nm + 90° 90° ❑ For For sele select ctor or mec mecha hani nism sm ⇒ page 85 . 85 . ❑ Self Self--lock lockiing ❑ Must Must be rene renewe wed d ifif re‐ re‐ moved ❑ 23 Nm ❑ Must Must be rene renewed wed if remove removed d

❑ Must be re renewed wed ifProtected removed remove by d copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with ❑ Tigh Tighte ten n wit with h 5 Nm + 90° 90° respect to the correctness of information in this document. Copyright by SEAT S.A. ❑ (Sel (Selec ecto torr unit unit)) ❑ Repairing ⇒ page 108 . 108 . ❑ Must Must be rene renewed wed if remove removed d ❑ Tigh Tighte ten n wit with h 5 Nm + 90° 90° ❑ 6 Nm


85


❑ For vehicl vehicles es with with star startt stop stop system system ❑ With captive captive seal seal (fitted (fitted shortly shortly after gearb gearbox ox was first first introduce introduced) d) ❑ Renewing with gearbox gearbox installed: installed: removing removing noise insulation insulation ⇒ General General body repairs, exterior; Rep. gr. gr. 66 ; Noise insulation; Assembly Assembly overview - noise insulation . ❑ 20 Nm ❑ Not fitted fitted in all gearb gearboxe oxes s ❑ (Gea (Gearr cha chang nge e pro prong ngs) s) ❑ Repairing ⇒ page 105 . 105 . ❑ ❑ ❑ ❑

If bearing mounting is separated separated from gearbox housing, then then mounting mounting must always be renewed. renewed. Remove Remove and press press on allotme allotment: nt: disassem disassemble ble and and assemble assemble input input shaft shaft ⇒ page 120 Disassemb Disassembly ly and and assemb assembly ly of the inpu inputt shaft shaft ⇒ page 120 Dismantlin Dismantling g and and assem assemblin bling g outpu outputt shaft shaft ⇒ page 133

❑ Must Must be be ren renewe ewed d ifif rem remove oved d ❑ To faste fasten n rever reverse se gea gearr pinion pinion axis axis ❑ Tigh Tighte ten n wit with h 25 25 Nm Nm + 45° 45°

86




It is not necessary to dismantle the selector fork group in order to dismantle and assemble selector segments, lock washers and angular contact ball bearings.

❑ Iden Identi tifi fica cati tion on ⇒ page 106 ❑ After After instal installat lation ion,, selec‐ selec‐ tor segment must still ro‐ tate freely ❑ 4 Units ❑ Removal ⇒ page 107 ❑ Pres Press s inn inner er race race into into outer race ⇒ page 108 ❑ Inst Insta alla llatio tion ⇒ page 108 ❑ Must Must be rene renewe wed d ifif re‐ re‐ moved ❑ Removal ⇒ page 107 ❑ Inst Insta alla llatio tion ⇒ page 107

❑ Iden Identi tifi fica cati tion on ⇒ page 106 ❑ The The seg segme ment nt must must ro‐ ro‐ tate freely after installing the lock washer. ❑ Sele Select ctor or for fork k with with sel selec ec‐‐ tor segment ⇒ page 107

❑ Sele Select ctor or seg segme ment nt is is per‐ per‐ manently connected to selector fork. ❑ Iden Identi tifi fica cati tion on ⇒ page 106 ❑ For the 5th/6t 5th/6th h gea gearr pro prong ng

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 Copyri ght by SEAT S.A.


87


♦ Clamp Clamping ing frame frame - VW 313313♦ Tighte Tighteni ning ng plat plate e - VW VW 401401♦ Tighte Tighteni ning ng plat plate e - VW VW 402402♦ Die Die - VW 412♦ Adap Adapte terr - T102 T10235 35--


88


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ♦ Die - VW VW 40 407♦ Tube Tube eleme element nt - VW VW 418 418 A♦ Thrus Thrustt piec piece e - T1008 T100800♦ Thrus Thrustt bloc block k - T100 T1008383♦ Plat Plate e - T100 T10083 83/1 /1-♦ Drip Drip tra tray y - V.A.G V.A.G 1306 1306-♦ or drip drip tray tray for for worksh workshop op hoist - VAS 6208♦ If 5th 5th gear gear whee wheell was was pressed off earlier ♦ Thru Thrust st pad pad - 3074 3074-♦ If 5th 5th gear gear whe wheel el was not not pressed off earlier ♦ Thru Thrust st pad pad - T103 T10375 75--



89

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ♦ Torq Torque ue wren wrench ch V.A.G 1331♦ -1-1- Thre Three e arm arm pulle pullerr - Kuk‐ Kuk‐ ko 30/1♦ -3-3- TwoTwo-ar arm m pulle pullerr - Kukk Kukko o 204/2♦ Hexag Hexagon on socket socket head head bolts bolts M8 x 15 ♦ Pull Puller er - T103 T10309 09-♦ Half Half sleev sleeve e - T1030 T10309/4 9/4-♦ If pull pulling ing off is is not not possi possible ble using half-sleeve men‐ tioned above, use ♦ Half Half sleev sleeve e - T1030 T10309/4 9/4AA♦ Adap Adapte terr - T103 T10309 09/5 /5-♦ Sealant ♦ Alloca Allocatio tion n ⇒ Electr Electroni onic c parts catalogue (ETKA)


– Secure gearbox to engine and gearbox support ⇒ page 117 . 117 . – Place the collecting collecting tray below below the gearbox. gearbox. – Drain gear gear oil.

90


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Remove clutch release release lever -A- with clutch clutch release release collar and guide sleeve -arrows-. – Remove right right flange shaft shaft securing bolt bolt -B-. – Screw 2 bolts into into flange flange and counterhold counterhold flange flange shaft shaft using a lever. – Remove the flanged flanged shaft with the compression spring, thrust thrust washer and conic ring.

– Unscrew the gearbox gearbox casing casing cover -arrow-arrow- and remove with care.


– Pull out pivot pivot pin -1- for 5th and and 6th gear gear selector fork fork -2- and and remove selector fork.

– Unscrew bolts -A- for inner inner bearing bearing races on input and and output output shafts. To do this, engage 5th gear -arrow 1- and 1st gear -arrow 2- and -arrow 3-. – Input shaft and and output shaft shaft are locked when when both gears gears are engaged. The two bolts can now be loosened.

♦ If the shafts are not being renewed, clean residual locking compound out of tapped holes using a thread tap. ♦ Pull off gear wheel for 6th gear with three arm puller - Kukko 30/1- . ♦ If necessary, gear wheel for 6th gear can be pulled off to stop on spindle with two arm puller - Kukko 204/2- . Then pull off further with three arm puller - Kukko 30/1- .


91

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Pull off 6th gear gear wheel wheel and inner race/roller bearing for output output shaft. A - Three-arm Three-arm puller puller - Kukko 30/130/1B - Hexagon socket head bolt - M8 x 15-

•

Synchrom Synchromeshe eshed d gear gear for 6th 6th gear: gear: pull pull off togeth together er with with inner inner race of cylindrical roller bearing for input shaft.

•

SynchroSynchro-hub hub for for 5th and and 6th 6th gear: gear: pull pull off togeth together er with with inner inner race for 6th gear needle bearing.

– First insert one one of the half sleeves sleeves - T10309/4T10309/4- or T10309/4A- . •

The half half sleeve sleeve must must be position positioned ed benea beneath th the synch synchrome romesh‐ sh‐ ed gear for 6th gear.

– If necessary, half half sleeve must be be pressed to end position. position. – Attach adapter adapter - T10309/5T10309/5- . – Place the thread insert - T10309/3T10309/3- into the half shell and lightly brace.

– Then fit the second second half sleeve sleeve - T10309/4T10309/4- or - T10309/4AT10309/4Aand plate tube - T10309/2- on assembly. Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised 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.

92



– First insert one one of the half sleeves sleeves - T10309/4T10309/4- or T10309/4A- . •

Half sleeve sleeve must must be be positio positioned ned beneath beneath synchro-r synchro-ring. ing.

– If necessary, half half sleeve must be be pressed to end position. position. – Position adapter adapter - T10309/5T10309/5- . – Place the thread insert - T10309/3T10309/3- into the half shell and lightly brace.

– Then fit the second second half sleeve sleeve - T10309/4T10309/4- or - T10309/4A T10309/4A-and plate tube - T10309/2- on assembly.

Once it has been removed, the synchromesh ring for 5th gear must always be renewed. – Remove selector selector gear for for 5th gear. gear.



93

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Remove the securing securing bolt bolt of the flange shaft -1-. To do do this, screw 2 bolts into flange and counterhold flange shaft with an assembly lever. – Remove flanged flanged shaft together together with compression compression spring. spring. – Remove sleeve sleeve -2- and needle bearing bearing -4-. -4-. – Unscrew the hexagonal hexagonal nut nut with the collar collar -5- from the the gear operation mechanism (to secure the reverse gear). – Remove bearing bearing mounting mounting securing securing bolts -6- from from input and and output shafts.

– Remove gear gear wheel for 5th gear -3-. -3-.

– The gear wheel for 5th gear -3-3- will be pressed pressed off later when when the bearing support for the deep groove ball bearing ⇒ page 126 . 126 . – Turn gearbox gearbox in support support bracket so that clutch housing housing is up‐ wards.

– Remove securing securing bolts from from clutch housing housing side for securing securing clutch housing to gearbox housing. – Remove clutch housing, if necessary necessary carefully carefully levering up all around along protruding housing flange and alternating be‐ tween sides, being careful not to damage sealing surfaces. – Do not not cant the clutch housing. This prevents damage to roller roller bearings and their bearing seats on the input and output shafts. Protected copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not – Remove differential differential -A- from from gearbox gearb oxbyhousing.


94


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Then remove remove oil collector collector -A- and oil oil guide -B- with magnet magnet from gearbox housing.

– Gearboxes Gearboxes for vehicles with with start-stop system: system: remove gear‐ gear‐ box neutral position sender - G701- -arrow-.

– Remove selector selector shaft with shaft shaft cover -A-. To To do so, the se‐ se‐ lector shaft must be brought into the gearbox neutral position. Then remove the bolts -arrows- and take the selector shaft out of the gearbox casing. – Remove pivot pivot pins -B- located located on underside underside of gearbox. gearbox. – Unscrew reverse reverse light switch - F4- -C-.

– Remove bolt bolt -A- for securing securing reverse reverse gear wheel wheel shaft. – Remove pivot pivot pins -B- located located on bottom bottom of gearbox. gearbox. Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised 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.

Do not remove the cover -arrows- to remove the gearbox.


95


– Press out input input shaft, output output shaft with bearing bearing mounting, mounting, se‐ lector mechanism (selector forks) and reverse gear together.

♦ Position gearbox housing so that dowel sleeves in the gearbox will not be damaged. ♦ When pressing out, get help from second mechanic to ensure components do not fall out.

– Press out input shaft, output output shaft with with gear gear wheel for 5th 5th gear gear -A-, bearing mounting, selector mechanism (selector forks) and reverse gear together.

♦ Position gearbox housing so that dowel sleeves in the gearbox will not be damaged. ♦ When pressing out, get help from second mechanic to ensure components do not fall out. – Press input and and output shafts shafts with deep groove groove ball ball bearing and, as appropriate, gear wheel for f or 5th gear off bearing mount‐ ing ⇒ page 120 . 120 .

♦ If bearing mounting with deep groove ball bearing was re‐ moved, press onto input shaft and output shaft ⇒ page 130 . . ♦ If needle roller bearing sleeve for synchromeshed gear for 5th gear was removed, press onto input shaft ⇒ page 130 . .

– Place the assembled components components of drive drive shaft -2- and output shaft -1- with bearing mounting/grooved ball bearing in the thrust block - T10080- . – Insert selector mechanism (selector forks) -4- in the shaft lock‐ ing collars. – Install reverse reverse gear shaft shaft -3- with reverse reverse gear.


96


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Screw guide guide pin - T10079T10079- onto stud stud (secures reverse reverse gear) gear) -arrow-.

– Place the assembled components components of of drive drive shaft -2- and output shaft -1- with bearing mounting/grooved ball bearing in the thrust block - T10080- . – Insert selector mechanism (selector forks) -4- in the shaft lock‐ ing collars. – Install reverse reverse gear shaft shaft -3- with reverse reverse gear. – Screw guide guide pin - T10079T10079- onto stud stud (secures reverse reverse gear) gear) -arrow-.

– Insert components compo nents together together in gearbox gea rboxor housing. housin g.purposes, Toses, dointhis, Protected by copyright. Copying for private commercial purpo part or in whole, is not permitted authorised through authorised by SEAT S.A. SEATfor S.A does not guarantee accept any liability with guide guide pinunless - T10079hole attachment ofor se‐ respect to the correctness of information in this document. Copyright by SEAT S.A. lector mechanism in gearbox housing. – Unscrew the guide guide pin - T10079T10079- .

♦ Selector Selector forks forks engage engage corr correctly ectly in lockin locking g collars. collars. ♦ Dimensio Dimension n -a- of the input input shaft shaft splines splines..

♦ The input shafts of the different gearboxes have different lengths as dimension -a- is different. ♦ A shim - T10083/1T10083/1- (3 mm thick) may have have to be fitted on the input shaft to ensure that the input shaft and the output shaft are always pressed in evenly. ♦ For this person, dimension -a- of the secondary shaft splines has to be measured.

Place washer - T10083/1- on input shaft ⇒ next illustration.


97



– Install bolt -A- for securing reverse gear gear wheel shaft. shaft. – Install pivot pin -B- in bottom of gearbox. gearbox.

Sealing cover -arrow- is installed.

– Install pivot pin -B- in top of gearbox. gearbox. – Move selector selector plates and selector shaft to neutral. – Apply sealant evenly to sealing surface of selector mechanism cover. – Install selector shaft with selector selector cover -A-. Then Then tighten the bolts -arrows-. – Screw in reversing reversing light switch switch - F4- -A- ⇒ page 85 . 85 .

98


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Gearbox Gearbox for vehicles with start/stop system: insert insert gearbox gearbox neutral position sender - G701- -arrow- and tighten securing bolt ⇒ page 85 . 85 .

– Using new bolts bolts -A-, tighten bearing mounting mounting for input and output shafts.

Tighten bolts alternately and diagonally, working from centre out‐ wards. – Tighten hexagon hexagon flange flange nut -B- for for selector mechanism mechanism (se‐ lector forks). – Insert input input and output shafts shafts together with gearbox gearbox housing into thrust block - T10083- .

The high shoulder -arrow- faces gearbox housing cover.


– Pressing on 5th gear wheel wheel – Set sleeve on gear wheel wheel for 5th gear gear item -2-.

– Fit the mobile mobile 5th gear pinion pinion -3- with with the needle needle bearing. bearing. – Fit the 5th gear gear synchromesh synchromesh ring on on the mobile pinion


99


The high shoulder -arrow- faces 5th gear and gearbox housing. – Press on synchro-hub synchro-hub and and locking collar collar for 5th and and 6th gear gear ⇒ page 99 . 99 .

– Heat the inner ring of the needle bearing of 6th gear to a max‐ imum of 100 °C and fit.

– Install synchromeshed synchromeshed gear gear for 6th gear gear with needle needle bearing bearing and synchro-ring.

– Fit the thrust ring ring -A- on top. top.

♦ Do not interchange inner races of cylindrical roller bearings of input and output shafts. ♦ For some gearboxes, the thrust washer -A- and the inner race Protected copyright. Copying for commercial purposes, purposes, in part or in whole, is not for the cylindrical cylindric al bearing -B-byare combined inprivate one or component.


•

They They can can be be press pressed ed on on toge togethe therr only. only.

– Heat the roller bearing bearing inner ring -B- to approx. approx. 100 ºC, and fit it onto the input shaft.

100



High collar faces sleeve. – Set locking collar collar -A- for 5th/6th 5th/6th gear to neutral position position to al‐ low 6th speed selector gear to turn while pressing on 6th gear wheel.

– Heat gear wheel for 6th gear to maximum maximum 100° C. – Pressing on gear wheel wheel for 6th gear gear When doing doing this, ensure ensure that teeth of gear wheel -B- for 6th gear and those of synchro‐ meshed gear -C- for 6th gear mesh properly. – Heat the roller bearing inner ring -A-A- to approx. approx. 100 ºC, and fit it onto the lay shaft.


– Next, place place the the oil collector -A- in the recess recess -1- and and in the drill drill hole -2- of the gearbox casing.

– Mount the oil oil guide -B- on the gearbox gearbox casing. – Place the magnet magnet on the oil guide -B-. -B-.


101

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Install differential differential -A-. – Apply sealant sealant evenly to sealing sealing surface. – Secure clutch housing to gearbox gearbox housing. housing. – Turn gearbox gearbox in support support bracket so that gearbox gearbox housing is is upwards.

– Before tightening tightening the fastening fastening bolts -A-A- 2 gears should should be engaged -arrow 1- to -arrow 3-.

– Insert the 5th 5th / 6th gear gear selector fork -2-2- and and slide slide the pivot pin pin -1- in onto stop in direction of -arrow-. – Apply sealant sealant - AMV 188 200 200 03- evenly evenly to sealing surface. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – permitted Tighten gearbox geauthorise arboxd by housing hou sing cover. unless authorised 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.

102


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Fit the two flanged flanged shafts shafts with the pressure pressure springs, springs, the the thrust thrust washers and the conical rings. – Install clutch release release lever together with release bearing bearing and guide sleeve ⇒ page 35 . 35 .

♦ ⇒ “5.4 Assembly overview - input shaft, output shafts, differ‐ ential, selector rods”, page 85 ♦ Gearbo Gearbox x housin housing g to clutch clutch housi housing ng ⇒ “6.1 Assembly overview - clutch housing”, page 111 ♦ Gear Gearbo box x hou housin sing g cover cover ⇒ “5.7 Exploded view - gearbox housing cover and 5th/6th gear”, page 103 ♦ Flange Flange shaft shaft to gearb gearbox ox (counte (countersun rsunk k bolt) bolt) ⇒ “2.1 Assembly overview - differential”, page 146

❑ Repairing ⇒ page 111 . 111 . ❑ Inst Instal alla lati tion on posi positi tion on ⇒ page 99 ❑ Must Must be be pre press ssed ed off off and and pressed on in gearbox‐ es for the 1.4 l engine ⇒ page 99

❑ Inst Instal alla lati tion on posi positi tion on ⇒ page 101

❑ From From the the out outpu putt sha shaft ft ❑ Mark Mark befo before re remo removi ving ng ❑ Do not not con confu fuse se with with the the inner ring of the input shaft roller bearing socket Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised d by SEAT S.A. SEAT S.A does not guarantee or accept any liability with outp output utrespect shaf shafttotauthorise the correctness of information in this document. Copyright by SEAT S.A.

❑ For For ❑ Self Self--lock lockiing ❑ Must Must be rene renewe wed d ifif re‐ re‐ moved ❑ M8 = 30 30 Nm Nm the then n tur turn n 90° further ❑ M10 = 75 Nm then turn 45° further

❑ With With cylind cylinder er roller roller bear‐ bear‐ ings for drive shaft shaft 1 and f or or drive shaft 2 ⇒ page 114 ❑ Repairing ⇒ page 115


103


❑ Must Must be be ren renewe ewed d ifif rem remove oved d ❑ Tigh Tighte ten n wit with h 5 Nm + 90° 90° ❑ ❑ ❑ ❑ ❑

For For the the inpu inputt shaf shaftt Self Self--lock lockin ing g Must Must be be ren renewe ewed d ifif rem remove oved d M8 = 30 Nm the then n turn turn 90° 90° furth further er M10 = 75 Nm then then turn turn 45° 45° furth further er

❑ For For the the inpu inputt shaf shaftt ❑ Mark Mark befo before re remo removi ving ng ❑ Do not confuse with the inner ring ring of the secondary secondary shaft shaft roller bearing socket

❑ For For the the inpu inputt shaf shaftt ❑ Instal Installed led in some some gea gearbo rboxes xes ❑ Allocatio Allocation n ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) (ETKA)

❑ ❑ ❑ ❑

One-piece for 6th gear Protected by copyright. private or commercial commercia purposes, in part or in whole, is not Allocatio Allocation n ⇒ Electron Elec tronic icCopying parts partsfor catalogu cata logue e (ETKA) (ETKl A) permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect correctness of information in this document. Copyright by SEAT S.A. Replac Replace e toge togethe therto r the with with slee sleeve. ve.

❑ ❑ ❑ ❑ ❑

Two-part for 6th gear Instal Installed led in some some gea gearbo rboxes xes Allocatio Allocation n ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) (ETKA) Replac Replace e toge togethe therr with with slee sleeve. ve.

❑ For 6th gear gear nee needle dle bear bearing ing.. ❑ Renew Renew togeth together er with needle needle bearing bearing.. ❑ Disma Dismantl ntling ing and and asse assemb mblin ling g ⇒ page 120 . 120 .

❑ For 5th gear gear sele selecto ctorr fork fork.. ❑ This will will be damag damaged ed when when the the input input shaft shaft is removed removed ❑ Must Must be be ren renewe ewed d ifif rem remove oved d

❑ For 5th gear

104



♦ Tighte Tightenin ning g plate plate - VW 402402♦ Thrus Thrustt piec piece e - 3290 3290/1/1♦ asse assemb mbly ly too tooll - 3301 3301-♦ Thrus Thrustt piec piece e - VW 431431♦ Separ Separati ation on cap cap - VW 472/2472/2♦ Assem Assembly bly mandr mandrel el - 10 10 206-



105

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ♦ Pres Pressi sing ng-o -off ff leve leverr 80-200-

♦ Asse Assemb mbly ly Man Mandr dril illl 10-508-

♦ Tens Tensio ioni ning ng tool tool 2070-

1-

1st/ 1st/2 2nd ge gear sel selec ec‐‐ tion group = 10.0 mm

2-

3rd 3rd/4th /4th gea gear se selec‐ lec‐ tion group = 78.6 mm

3-

Pro Prongs of 5th/6 th/6th th gear with gear se‐ lection = 79.5 mm.

106




Measurement -a- =78 mm.

– Clamp selector selector fork in vice with protective jaw jaw covers -B-. – Lever off lock lock washer -A- in -direction of arrow-.


– Press the spring spring washer in the the groove groove of the gear change with a handled socket spanner.

The segment must rotate freely after installing the lock washer. A - Socket spanner spanner with handle, handle, size 10 B - Protection gags

Do not bend selector forks when removing and installing the ball bearing.


107


Inner race must engage in outer race.

The groove on the pressure tool - 3290/1- facing towards the ball bearing


108



♦ Centri Centring ng chuck chuck - 12-55 12-5511♦ Mand Mandre rell - 202 20266♦ Thrus Thrustt piec piece e - T4000 T400088♦ Torq Torque ue wre wrenc nch h - V.A. V.A.G G 1331♦ Seala Sealant nt - AMV 188 188 200 200 0303-

Tube - T10203 – Remove selector selector mechanism mechanism ⇒ page 85 . 85 .



109


– Remove outer outer part of angled angled rod. – Carefully lever lever out angled angled rod with a screwdriver. screwdriver.

Marking -1- aligns with marking -2- on selector cover. – Install selector mechanism ⇒ page 85 . 85 .


110



❑ Remo Remove ve and and inst instal alll ⇒ Item 1 (page 146)

❑ Remo Remove ve and and inst instal alll ⇒ page 88 ❑ Assembling ⇒ page 146


❑ Must Must be rene renewe wed d ifif re‐ re‐ moved ❑ Tigh Tighte ten n wit with h 5 Nm + 90° 90° ❑ Repairing ⇒ page 111 . 111 . ❑ Repairing ⇒ page 111 . 111 . ❑ With With guid guide e sle sleev eve e and and clutch release collar ❑ Remo Remove ve and and inst instal alll ⇒ page 111 ❑ Must Must be rene renewe wed d ifif re‐ re‐ moved ❑ 5Nm + 90º

6. Gearbox housing, clutch housing

111


❑ If rep repla lace ced, d, adju adjust st the the differential ⇒ page 152 ❑ Repl Replac ace e afte afterr rem remov oval al ⇒ page 131 ❑ To remo remove ve and and ins insta tall ll,, remove gearbox ❑ Remo Remove ve any any tra trace ces s of of grease ❑ Lubr Lubric icat ate e surf surfac ace e whic which h contacts ball head stud with grease - G 000 100❑ 20 Nm ❑ Repl Replac ace e afte afterr rem remov oval al ⇒ page 143 ❑ Tigh Tighte teni ning ng tor torqu que e ⇒ page 119 ❑ for the differ differen entia tiall gea gear r ❑ Dete Determ rmin ine e thic thickn knes ess s ⇒ page 152

❑ for the differ differen entia tiall gea gear r ❑ Pres Pressi sing ng out out of and and into into clutch housing ⇒ page 146 ❑ If rep repla lace ced, d, adju adjust st the the differential ⇒ page 152

Protected by copyright. Copying for private or commercial purposes, purposes, in pa rt or in whole, is not n ot permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or a ccept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Must Must be be ren renewe ewed d ifif rem remove oved d ❑ Tigh Tighte ten n wit with h 5 Nm + 90° 90° ❑ for the dif ferential ferential gear gear ❑ Pulling Pulling out out of and and pressin pressing g into into clutch clutch housi housing ng ⇒ page 146 ❑ If repla replaced, ced, adjust adjust the differen differential tial ⇒ page 152 ❑ 2 Units ❑ If repla replaced, ced, adjust adjust the differen differential tial ⇒ page 152 ❑ Tigh Tighte teni ning ng torq torque ue ⇒ page 119 ❑ Replace after removal removal ⇒ page 142

112



❑ For the gear gear select selection ion shaft shaft ❑ Press out ⇒ page 110 ❑ Press on ⇒ page 110 ❑ Apply Apply sealant sealant on on sealing sealing surfa surfaces ces before before screw screwing ing on ❑ Allocatio Allocation n ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) (ETKA) ❑ Insert Insert in groo groove ve of cylind cylindrica ricall roller roller bear bearing ing ❑ Insert Insert in groo groove ve of cylind cylindrica ricall roller roller bear bearing ing ❑ For For the the inpu inputt sha shaft ft ❑ Pullin Pulling g out out and and pres pressin sing g in in ⇒ page 120 ❑ From From the the out outpu putt sha shaft ft ❑ Pullin Pulling g out out and and pres pressin sing g in in ⇒ page 133 ❑ In some some gear gearbo boxe xes s ❑ Insert Insert into into hole hole in clutc clutch h housi housing ng..



113


❑ Tigh Tighte ten n diag diagon onal ally ly,, to‐ gether with bearing plate ❑ 2 Nm ❑ For secur securing ing cylind cylindric rical al roller bearing ❑ Instal Installat lation ion posit position ion:: de‐ de‐ pression for the screws must point to the gear housing. ❑ Not Not inst instal alle led d in all all gea gear‐ r‐ boxes; alternatively se‐ cured with bolts ⇒ page 116 Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness ❑ For Fo r the the inpu input t shaf shafttof information in this document. Copyright by SEAT S.A.

❑ Do not not int inter erch chan ange ge wit with h roller bearing for output shaft ❑ Pull out ⇒ page 115 ❑ Press on on ⇒ page 116 ❑ Vari Variou ous s mean means s of sec secur ur‐‐ ing ⇒ page 116 ❑ From From the the out outpu putt sh shaft ❑ Do not not int inter erch chan ang ge with roller bearing for input shaft ❑ Pull out ⇒ page 115 ❑ Press on on ⇒ page 116 ❑ Vari Variou ous s mean means s of sec secur ur‐‐ ing ⇒ page 116

114



♦ Die - VW VW 41 412♦ Inla Inlay y sock socket et - 4040-21 21-♦ Suppo Support rt bridg bridge e - 20112011♦ -1-1- Inter Interna nall pulle pullerr - Kukk Kukko o 21/5♦ -4-4- Coun Counter ter suppo support rt - Kukk Kukko o 22/2♦ E.g. E.g. Hot Hot air air gun gun - V.A. V.A.G G 1416- .

A - Internal puller puller 28...37 mm , e.g. -Kukko 21/5B - Support bracket , ex. -Kukko 22/1-



115


– Heat gearbox gearbox housing cover with, for example, example, hot air air blower - V.A.G 1416- to about 100°C in vicinity of bearing seat. – Insert roller bearing after after heating housing and and push into posi‐ tion under workshop press until heat exchange has taken place.

Roller bearings must be pressed fully home into cover. Do not try to tighten via bolts on base plate. – Secure cylindrical cylindrical roller bearing.

The cover was adapted.

1. - Secured with bearing plate -A- and countersunk head bolts M 4 x 14 -arrows-

6

2. - Secured with countersunk head bolts M 4 x 12 -arrows-

2

♦ Coun Counte ters rsun unk k bol boltt ⇒ page 114


116



♦ Engine Engine and and gearbo gearbox x support support - VW 540540-

♦ Adap Adapte terr - T102 T10235 35--

♦ Clampi Clamping ng fra frame meProtected - VW by 313 313copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised 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.

– Secure gearbox gearbox to engine engine and gearbox gearbox support support - VW 540540-arrows-.

7. Installing to engine and gearbox support

117


♦ Socket Socket bit - 3357- for for oil filler plug plug with multi-p multi-point oint socket socket head head bolt


Gearbox oil ⇒ Electronic parts catalogue (ETKA) – Remove noise noise insulation ⇒ General body body repairs, repairs, exterior; Rep. gr. 66 ; Noise insulation; insulation; Assembly overview - noise noise in‐ sulation . – To check gear gear oil, remove remove oil plug -arrow-. -arrow-.

– If necessary, fill with gear oil to lower lower edge of filler hole. – Tighten bolt bolt -arrow-.


118



I - Oil filler or oil drain plug with multi-point socket head, 25 Nm II - Oil filler or oil drain plug with hexagon socket head, 30 Nm – Install noise noise insulation insulation ⇒ General General body repairs, exterior; Rep. gr. 66 ; Noise insulation; insulation; Assembly overview - noise noise insula‐ tion .


8. Gear oil

119


♦ When installing new sliding gears or a new input shaft, all details of the ⇒ Electronic parts catalogue catalo gue ETKA and technical data must be observed. ♦ Install all bearings, synchromeshed gears and synchro-rings on input shaft with gear oil. ♦ Do not mix up synchromesh rings. If reused, always install with the original synchromeshed gear.

❑ Remo Remove ve and and inst instal alll ⇒ page 103

❑ Comb Combin ined ed with with thru thrust st washer ⇒ page 103 ❑ Mark Mark befo before re remo removi ving ng ❑ Do not not con confu fuse se with with the the inner ring of the secon‐ dary shaft roller bearing socket ❑ Remo Remove ve and and inst instal alll ⇒ page 88 Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised 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.

❑ Comb Combin ined ed with with inne inner r race of cylindrical roller bearing ⇒ page 103

❑ Che Check for for we wear ⇒ page 128 ❑ for 6th gear ❑ Repl Replac ace e tog toget ethe herr wit with h sleeve. ❑ Two-part ⇒ page 103 ❑ For For 6th 6th gear gear need needle le bearing. ❑ Rene Renew w toge togeth ther er with with needle bearing. ❑ Remo Remove ve and and inst instal alll ⇒ page 88

120

Rep. gr.35 - Gears, shafts


❑ Remo Remove ve and and inst instal alll ⇒ page 88 ❑ Dism Disma antlin tling g ⇒ page 130 ❑ Insert the unit comprising comprising locking locking collar collar and synchromesh synchromesh body of 5th / 6th gear gear ⇒ page 130 and 130 and ⇒ page 130 . 130 . ❑ Inst Instal alla lati tion on pos posit itio ion n ⇒ page 130 ❑ Will be be damage damaged d during during remov removal al of inpu inputt shaft shaft ❑ Must Must be rene renewed wed if remove removed d ❑ Che Check for for we wear ⇒ page 128

❑ For 5th gear ❑ Renew Renew togeth together er with with sleeve sleeve ❑ ❑ ❑ ❑

For 5th gear gear need needle le bearin bearing g Replace Replace together together with needle needle bearing bearing Press Press off with beari bearing ng mountin mounting g with deep deep groove groove ball ball bearing bearing Press on ⇒ page 130

❑ Repairing ⇒ page 111 . 111 . ❑ Renew Renew deep groove groove ball ball bearing bearing only only togethe togetherr with bearing bearing mounti mounting ng ❑ If bearing mounting is separated separated from gearbox housing, then mounting mounting must always be renewed. renewed. ❑ Gear Gear whe wheel el for for 5th 5th gear gear could be removed removed by hand: Press off without gear wheel for 5th gear ⇒ page 126 . 126 . ❑ Gear wheel wheel for 5th 5th gear could not not be removed removed by hand: hand: Press Press off with gear gear wheel wheel for 5th gear ⇒ page 126 . 126 . ❑ Press on ⇒ page 130 ❑

Protected by copyright. Copying for private or comm commercial ercial purposes, in i n part or in whole, is not permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or guarantee or accept any liability with the correctness of information this document. Copyright SEAT S.A. Cleanrespect any any totraces of fixing agent agentinfrom the the threaded thread edbyholes in the input input

shaft using using a tap. tap.

❑ for 3rd gear

❑ Che Check for for we wear ⇒ page 128 ❑ ❑ ❑ ❑ ❑

Press Press off with 3rd gear synchrom synchromeshe eshed d gear gear ⇒ page 126 Dism Disma antlin tling g ⇒ page 127 Installati Installation on position position of of the locking locking collar collar/sync /synchro hro-hub -hub.. ⇒ page 127 Assembling ⇒ page 127 Press on ⇒ page 128

❑ ❑ ❑ ❑

For 4th gear gear need needle le bearin bearing g Renew Renew toge togethe therr with nee needle dle bear bearing ing.. Press Press off with 3rd gear synchrom synchromeshe eshed d gear gear ⇒ page 126 Press on ⇒ page 128

1. Input shaft

121


❑ for 4th gear ❑ Renew Renew togeth together er with with slee sleeve ve ❑ Che Check for for we wear ⇒ page 128

❑ Press ou out ⇒ page 126 ❑ Press on on ⇒ page 128 ❑ Must Must be be ren renewe ewed d ifif rem remove oved d Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with ❑ Dete Determ rmin ine e thi thick ckne ness ss ⇒ page 129 respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ ❑ ❑ ❑

Circlip Pull out ⇒ page 125 Press on on ⇒ page 126 Installation position: the securing securing ring ring of the bearing bearing must must point to the input shaft shaft

❑ Repairing ⇒ page 111 . 111 . ❑ Inst Instal alla lati tion on posi positi tion on ⇒ page 130

❑ Inst Instal alla lati tion on posi positi tion on ⇒ page 127

122



♦ Tighte Tightenin ning g plate plate - VW 401401♦ Tighte Tightenin ning g plate plate - VW 402402♦ Die - VW VW 40 407♦ Die - VW VW 41 412♦ Tube Tube eleme element nt - VW VW 415 415 A♦ Tube Tube eleme element nt - VW VW 422 422--


1. Input shaft

123

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ♦ Separ Separati ation on cap cap - VW 472 472/2/2♦ Tube Tube eleme element nt - VW VW 516 516-♦ Exte Extens nsio ion n - 30-2 30-233♦ Inlay Inlay socket socket - 3030-10 1000♦ Thrus Thrustt piec piece e - T1008 T100800♦ Thrus Thrustt piec piece e - T1008 T100811-


♦ Plat Plate e - T100 T10083 83/1 /1--

124


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ♦ Thrus Thrustt bloc block k - T100 T1008383♦ Tighte Tightenin ning g plate plate - T100 T10084 84 A♦ -1-1- Inter Interna nall pulle pullerr - Kukk Kukko o 21/5♦ -4-4- Coun Counter ter suppo support rt - Kukk Kukko o 22/2-

– When pulling pulling out, squeeze squeeze together together retaining ring -arrow-arrow- of cylindrical roller bearing, using pliers -C-. A - Support bracket bracket , ex. -Kukko -Kukko 22/1B - Internal puller 30...37 mm , e.g. -Kukko 21/5-


1. Input shaft

125


– Support gearbox housing with tube - VW 415 AA- (not (not visible in figure) directly below bearing support. – When pressing pressing in, compress compress circlip -arrow-arrow- for roller roller bearing bearing using pliers -A-. – Remove the pliers pliers before before the bearing bearing is in its final installation installation position. The securing ring should insert into the groove of the clutch pan.

– Slide locking collar for 1st and and 2ndgear 2ndgear onto 2ndgear. 2ndgear. – Then slide slide pressure pressure plate plate - T10084 T10084 A- onto input shaft shaft to stop from side.

– Slide locking collar for 1st and and 2ndgear 2ndgear onto 2ndgear. 2ndgear. – Then slide slide pressure pressure plate plate - T10084 T10084 A- onto input shaft shaft to stop from side.


– Remove circlip. circlip. – Press off roller roller bearing bearing inner race together with thrust thrust washer, washer, 4th speed selector gear with needle bearing, locking collar and synchronising synchronisi ng hub for 3rd and 4th gear and 3rd speed selector gear.

126



– First remove retaining ring with Circlip pliers - VW 161 161 A- . – Position splitter splitter -B- behind behind teeth of synchromeshe synchromeshed d gear for 4th gear which engage in the other gear wheel (not dog teeth) and tension. A - Puller , e.g. e.g. -Kukko 18/1B - Splitter 12...75 mm , e.g. -Kukko 17/1C - Protection gags

1-

Spring

2-

Mobile element

3-

Synchromesh hu hub

4-

Locking el element

– The locking collar is fitted onto onto the synchro-hub. synchro-hub. Deepest notches -arrow A- for locking pieces in synchro-hub and notches -arrow B- in locking collar must align.

•

Locking Locking collar collar has has been been pushed pushed over synchro synchro hub. hub.

– Fit the locking elements in the the deepest grooves grooves -arrows-arrows- and fit the elastic rings off-set by 120º. Angled end of spring must locate in hollow lockingProtected piece.by copyright. Copying for private or commercial purposes, in part or in whole, is not


The groove on the front -arrow- should face towards 4th gear.

1. Input shaft

127


– Press synchro-ring synchro-ring onto cone of synchromeshed synchromeshed gear and measure gap -a- using feeler gauge.

3rd, 4th, 5th and 6th gear

1.1 … 1.7 mm

0.5 mm

Installation position: The high collar faces 3rd gear wheel

– After installing the sleeve -A-, -A-, mount the needle bearing bearing and the mobile pinion of 4th gear together with the thrust ring.


128



– Insert a 2.0 mm thick retaining retaining ring -A-A- in groove of input input shaft and press upwards -arrow-. – Measure distance between inner race -B- and and installed installed retain‐ ing ring -A- using feeler gauge -C-. – Remove retaining retaining ring used for measuring measuring purposes. purposes. – Select the securing securing ring using the table. table.

Allocate retaining retaining rings using using ⇒ Electronic parts parts catalogue (ET‐ KA) . 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 The following circlips (retaining rings) are available: respect to the correctness of information in this document. Copyright by SEAT S.A.

0.05 … 0.14

2.0

0.05 … 0.15

0.15 … 0.24

2.1

0.05 … 0.15

0.25 … 0.34

2.2

0.05 … 0.15

0.35 … 0.44

2.3

0.05 … 0.15

0.45 … 0.51

2.4

0.05 … 0.10

♦ The input shafts of the different gearboxes have different lengths as the dimension of the splines - dimension -a- - are different (the figure shows the shaft mounted). ♦ To ensure that bearing support is always evenly pressed onto shafts, it is necessary for shafts always to be inserted evenly into thrust block - T10083- . ♦ If necessary, insert a shim - T10083/1T10083/1- (3 mm thick) into fitting hole for input shaft ⇒ page 129 . . ♦ For this person, dimension -a- of the secondary shaft splines has to be measured.

Insert shim - T10083/1- ⇒ next figure.

1. Input shaft

129


– Before fitting, fitting, heat the allotment allotment to a max. max. of 100 °C.

1-

Spring

2-

Mobile el element

3-

Synchromesh hu hub

4-

Locking el element

– The locking collar is fitted onto onto the synchro-hub. synchro-hub. Deepest notches -arrow A- for locking pieces in synchro-hub and notches -arrow B- in locking collar must align.

•

Locking Locking collar collar has has been been pushed pushed over over synchro synchro hub.

– Fit the locking elements in the the deepest grooves grooves -arrows-arrows- and fit the elastic rings off-set by 120º. •

Angled Angled end end of of spring spring must must locate locate in hollow hollow locking locking piece piece..

130




♦ Pulle Pullerr hooks hooks - T201 T20143 43/1/1-


♦ Thrus Thrustt piec piece e - T4000 T400088-

♦ Seal Sealin ing g grea grease se ♦ For grea grease se allocat allocation, ion, refer refer to ⇒ Electron Electronic ic parts parts catalogu catalogue e (ETKA) . – Remove manual manual gearbox. gearbox. – Remove clutch release lever lever together together with release bearing and guide sleeve ⇒ page 35 . 35 . – Lever out oil oil seal for input input shaft.

Do not damage running surface of input shaft for oil seal.

1. Input shaft

131

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Fill space space between between sealing lip and and dust dust lip -arrow- with sealing sealing grease . – Lightly moisten moisten outer circumference circumference of of oil seal with gear gear oil.

– Install clutch release release lever with with release bearing bearing and and guide sleeve ⇒ page 35 . 35 . – Installing gearbox gearbox ⇒ page 72 . 72 .


132



♦ When installing new gears or new input shaft, refer to ⇒ Electronic parts catal catalogue ogue (ETKA) and technical data. ♦ Install all bearings, synchromeshed gears and synchro-rings on output shaft with gear oil. ♦ Do not mix up synchromesh rings. If reused, always install with the original synchromeshed gear.

❑ Repairing ⇒ page 111 . 111 . ❑ ❑ ❑ ❑

Circlip Pull out ⇒ page 136 Press on ⇒ page 136 Instal Installat lation ion positi position on:: re‐ re‐ taining ring in bearing faces output shaft

❑ If an an inn inner er race race as as bea bear‐ r‐ ing seat for cylindrical roller bearing is present, it cannot be removed from output shaft ❑ Chec Check k the the sea seati ting ng or the the inner cylindrical bearing ring for damage or scor‐ ing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with ❑ If the therespect seatin seating g or or the the inner inner to the correctness of information in this th is document. Copyright by SEAT S.A. cylindrical bearing ring shows scoring or dam‐ age then replace the secondary shaft and the cylindrical roller bearing ❑ Fitt Fittin ing g loca locati tion on:: Colla Collar r faces 3rd gear ⇒ page 137

❑ Fitt Fittin ing g loca locati tion on:: Colla Collar r faces 4th gear ⇒ page 137

❑ for 2n 2nd gear

2. Secondary shaft

133


❑ Che Check for for we wear ⇒ page 137 ❑ Inst Instal alla lati tion on posi positi tion on ⇒ page 138 ❑ Set Set on on inn inner er ring ring.. ❑ Replace Replace this this if there there are are groove grooves s or treads treads caused caused by wear wear ❑ Inst Instal alla lati tion on posi positi tion on ⇒ page 138 ❑ Che Check for for we wear ⇒ page 137 ❑ Inst Instal alla lati tion on posi positi tion on ⇒ page 138 ❑ ❑ ❑ ❑ ❑

Press Press off together together with with 2nd speed speed selector selector gear gear after after removing removing circlip circlip ⇒ page 137 Dism Disma antlin tling g ⇒ page 138 Assemblin Assembling g locking locking collar/sy collar/synchr nchronis onising ing hub ⇒ page 138 and 138 and ⇒ page 138 Inst Instal alla lati tion on posi positi tion on ⇒ page 138 Press on on ⇒ page 139

❑ Must Must be be ren renewe ewed d ifif rem remove oved d ❑ Press ou out ⇒ page 136 ❑ Ins Instal tallati latio on ⇒ page 139 ❑ Che Check for for we wear ⇒ page 137 ❑ Assemble Assemble so that that notches notches engage engage in locking locking pieces pieces of locking locking collar. collar. ❑ Inse Insert rt in in sync synchr hroo-ri ring ng ❑ Inst Instal alla lati tion on posi positi tion on ⇒ page 139 Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with ❑ Replac Replace e this this ifif there there are are groo grooves ves or treads tread by ofwear respect s to caused the correctness information in this document. Copyright by SEAT S.A. ❑ Che Check for for we wear ⇒ page 137 ❑ Check Check that that the the tabs tabs show show no signs signs of wear wear ❑ Inst Instal alla lati tion on posi positi tion on ⇒ page page 139 ❑ Of 1st ge gear ❑ Inst Instal alla lati tion on posi positi tion on ⇒ page 140 ❑ ❑ ❑ ❑ ❑

Renew Renew deep groove groove ball ball bearing bearing only together together with with bearing bearing mounting mounting If bearing mounting is separated separated from gearbox housing, then then mounting mounting must always be renewed. renewed. Press Press off without without gear gear whee wheell for 5th gear gear ⇒ page 126 Press Press off off with gear gear whe wheel el for for 5th gea gearr ⇒ page 126 Press on on ⇒ page 130

❑ Repairing ⇒ page 111 . 111 . ❑ Remo Remove ve and and inst instal alll ⇒ page 103 ❑ Mark Mark befo before re remo removi ving ng

134


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ❑ Do not confuse confuse with with the inner inner ring of of the input input shaft roller roller bearin bearing g socket socket ❑ Remo Remove ve and and inst instal alll ⇒ page 88 ❑ Inst Instal alla lati tion on posi positi tion on:: ⇒ page 101 ❑ Remo Remove ve and and inst instal alll ⇒ page 88 ❑ Remo Remove ve and and inst instal alll ⇒ page 88 ❑ Inst Instal alla lati tion on pos posit itio ion n ⇒ page 99 ❑ Must be be pressed pressed off off and presse pressed d on in gearbo gearboxes xes for the the 1.4 l engine engine ⇒ page 99 ❑ Inst Instal alla lati tion on pos posit itio ion n ⇒ page 138

♦ Tighte Tightenin ning g plate plate - VW 402402♦ Die - VW VW 40 407♦ Tube Tube eleme element nt - VW VW 415 415 A♦ Thrus Thrustt piec piece e - VW 432432♦ Inlay Inlay socket socket - 30-1 30-100 00--


2. Secondary shaft

135

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ♦ -1-1- Inter Internal nal puller puller - 11Kukko 21/5-

♦ Supp Suppor ortt brac bracke kett - 44Kukko 22/1-

– When pulling pulling out, squeeze together re‐ taining ring -arrow- of cylindrical roller bear‐ ing, using pliers -C-. A - Support Support bracket , ex. -Kukko 22/1B - Internal puller 30...37 mm , e.g. -Kukko 21/5-

– Support the clutch casing by by placing the tubular section section - VW 415 A- (not seen in the fig.) directly below the allotment. – When pressing pressing in, compress compress circlip -arrow-arrow- for roller roller bearing bearing using pliers -A-. – Remove the pliers pliers before before the bearing bearing is in its final installation installation position. The securing ring should insert into the groove of the clutch pan. – Press bearing mounting with grooved ball bearing off the the drive drive shaft and output shaft ⇒ page 126 . 126 .

A - Protective gloves


136



– After removing removing retaining retaining ring, press press off synchromeshed synchromeshed gear gear for 2nd gear together with locking collar and synchro-hub.

– Fit 4th gear wheel -A- onto onto output shaft. shaft. Protected by copyright. Copying for private or commercial purposes, 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.

The collar -arrow 1- should face towards the 3rd gear pinion -B-. – Fit the securing securing rings -2-2- and -3-. – Fit 3rd gear gear wheel -B- onto output output shaft.

The collar -arrow 2- should face towards the 4th gear pinion -A-. – Fit the securing securing ring -1-. -1-.

– Press the inner inner ring against the mobile pinion cone and meas‐ ure the distance “a” with a thickness jig.

1st and 2nd gears

0.75 … 1.25 mm

0.3 mm

– Press synchro ring, outer ring and inner inner ring against against tapered tapered seat on selector gear and measure gap “a” using a feeler gauge.

1st and 2nd gears

1.2 … 1.8 mm

0.5 mm

2. Secondary shaft

137


– Fit the interior interior ring -A- onto onto the mobile mobile pinion for for 2nd gear. gear. Angled lugs lugs -arrow 11- face outer ring ring -B-. – Fit the outer ring -B-. Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed gear. – Fit the synchroniser synchroniser ring -C-. The recesses -arrow 4- locate on the tabs -arrow 1- of the inner ring -A-.

1-

Spring

2-

Mobile el element

3-

Synchromesh hu hub

4-

Locking el element

– The locking collar is fitted onto onto the synchro-hub. synchro-hub.

After assembly, assembly, the groove on the face -arrow -arrow A- and and the higher higher shoulder -arrow B- of synchro-hub face outer splines of the lock‐ ing collar -arrow C-. The deeper grooves -arrow D- of the locking piece in the syn‐ chromesh must be aligned with the grooves -arrow E- of the mobile sleeve.

•

Locking Locking collar collar has has been been pushed pushed over over synchro synchro hub.

– Fit the locking elements in the the deepest grooves grooves -arrows-arrows- and fit the elastic rings off-set by 120º. Angled end of spring must locate in hollow locking piece. Protected by copyright. Copying for private or commercial purposes, 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.

138



Groove in locking collar for selector fork faces 1st gear and teeth for reverse gear face 2nd gear. – Turn the synchromesh synchromesh ring ring so that the notches coincide coincide with the locking elements.

– Fit the 1st gear gear securing ring ring on the mobile mobile sleeve / synchro‐ mesh assembly.

The tabs

Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with respect to the correctness of information document. Copyright by SEAT S.A. -arrows- point towards the teeth of thein this reverse gear.

The tabs -arrows 1- insert into the recesses -arrows 2- of the syn‐ chromesh ring -B-.

2. Secondary shaft

139


The highest collar -A- should face 2nd gear -B-. The collar grooves -arrows- engage into the outer ring tabs ⇒ page 139 . 139 . – Press bearing bearing mounting mounting with grooved grooved ball bearing bearing onto the the drive shaft and output shaft ⇒ page 130 . 130 . – Before fitting, fitting, heat the allotment allotment to a max. max. of 100 °C.


140



❑ For For the the inpu inputt sha shaft ft ❑ Repl Replac ace e aft after er remo remova vall ⇒ page 131 ❑ For For rig right ht flan flange ge shaf shaftt ❑ Repl Replac ace e aft after er remo remova vall ⇒ page 143 ❑ For For lef leftt fla flang nge e sha shaft ft ❑ Repl Replac ace e aft after er remo remova vall ⇒ page 142 ❑ of the the sel selec ecti tion on shaf shaftt ❑ Repl Replac ace e aft after er remo remova vall ⇒ page 57


1. Sealing rings

141


♦ Univer Universal sal tool tool - VW 771771♦ Puller Puller hooks hooks - VW 771/37 771/37-♦ Thrus Thrustt piec piece e - T1016 T101600♦ Drip Drip tra tray y - V.A.G V.A.G 1306 1306-♦ or drip drip tray tray for for work worksho shop p hoist - VAS 6208♦ Drip Drip tray tray for for works workshop hop hoist hoist - VAS 6208♦ Torq Torque ue wren wrench ch V.A.G 1331♦ Seal Sealin ing g grea grease se ♦ For For grease grease allo allocat cation ion,, refer refer to ⇒ Electronic parts cata‐ cata‐ logue (ETKA) .


– Remove the left left hand side wheel. – Remove noise noise insulation ⇒ General body body repairs, repairs, exterior; Rep. gr. 66 ; Noise insulation; insulation; Assembly overview - noise noise in‐ sulation . – Turn the steering steering toward toward the left. – Unbolt the the drive shaft from from the flanged shaft ⇒ Running gear, axles, steering; steering; Rep. Rep. gr. 40 . – Raise drive shafts as high high as possible and secure, taking care not to damage surfaces. – Place drip tray tray under the the gearbox. gearbox.

142

Rep. gr.39 - Final drive - differential

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Extract the bolt bolt fastening the flanged shaft. shaft. To do so, thread thread 2 bolts on the flange and lock the shaft using the assembly lever. – Remove flanged flanged shaft together together with compression compression spring. spring.

– Remove the flanged shaft shaft seal with the universal universal tool - VW 771- and the extraction hook - VW 771/37- .

– Drive in new seal seal to stop, being being careful not not to cant seal. – Half-fill space between sealing sealing lip and dust lip with sealing sealing grease . – Insert flange shaft. – Secure flange flange shaft with countersunk countersunk bolt bolt and tighten tighten to 25 Nm. – Screw the driveshaft driveshaft to the flanged flanged shaft shaft ⇒ Running gear, gear, shafts, steering; steering; Rep. Rep. gr. 40 . – Check gear oil level and top up to lower lower edge of oil oil filler hole if necessary ⇒ page 118 . 118 . – InstallProtected noise noisebyinsulation insu lation ⇒ General General body repairs, exterior; Rep. copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not gr. permitted 66 ; Noise insulation; insulation ; Assembly overview noi noise insula‐ unless authorised by SEAT S.A. SEAT S.A does not guaranteese or accept any liability with respect to the correctness of information in this document. Copyright by SEAT S.A. tion . – Install wheel ⇒ Running gear, gear, axles, steering; steering; Rep. gr. gr. 44 ; Wheels and tyres; Tightening torque of the wheel bolts .

♦ Flang Flange e shaft shaft to gea gearbo rbox x ⇒ page 146

1. Sealing rings

143


♦ Univer Universal sal tool tool - VW 771771♦ Puller Puller hooks hooks - VW 771/37 771/37-♦ Thrus Thrustt piec piece e - T1016 T101600♦ Drip Drip tra tray y - V.A.G V.A.G 1306 1306-♦ or drip drip tray tray for for work worksho shop p hoist - VAS 6208♦ Drip Drip tray tray for for works workshop hop hoist hoist - VAS 6208♦ Torq Torque ue wren wrench ch V.A.G 1331♦ Seal Sealin ing g grea grease se ♦ For For grease grease allo allocat cation ion,, refer refer to ⇒ Electronic parts cata‐ cata‐ logue (ETKA) .


– Remove noise noise insulation ⇒ General body body repairs, repairs, exterior; Rep. gr. 66 ; Noise insulation; insulation; Assembly overview - noise noise in‐ sulation . – Remove drive shaft heat shield, if present present -arrows- ⇒ Running gear, axles, steering; Rep. gr. 40 . – Unbolt the the drive shaft from from the flanged shaft ⇒ Running gear, axles, steering; steering; Rep. Rep. gr. 40 . – Raise drive shaft shaft as high as possible possible and secure, taking care not to damage surfaces. – Place drip tray tray under the the gearbox. gearbox.

144


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Extract the bolt bolt fastening the flanged shaft. shaft. To do so, thread thread 2 bolts on the flange and lock the shaft using the assembly lever. – Remove flanged flanged shaft together together with compression compression spring. spring.

– Pull out flange shaft oil seal using multi-purpose multi-purpose tool - VW 771and puller hooks - VW 771/37- or prise out using a lever.

Protected by copyright. Copying for private or commercial purpos es, in part or in whole, wh ole, is not permitted unless authorised 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.

– Drive in new seal seal to stop, being being careful not not to cant seal. – Half-fill space between sealing sealing lip and dust lip with sealing sealing grease . – Insert flange shaft. – Secure flange flange shaft with countersunk countersunk bolt bolt and tighten tighten to 25 Nm. – Install drive shafts shafts ⇒ Running gear, gear, axles, steering; steering; Rep. gr. gr. 40 ; Drive shaft; Assembly overview - drive shaft .

– Attach the drive drive shaft heat shield, shield, if present present -arrows- ⇒ Run‐ ning gear, axles, steering; Rep. gr. 40 . – Check gear oil level and top up to lower lower edge of oil oil filler hole if necessary ⇒ page 118 . 118 . – Install noise noise insulation insulation ⇒ General General body repairs, exterior; Rep. gr. 66 ; Noise insulation; insulation; Assembly overview - noise noise insula‐ tion .

♦ Flang Flange e shaft shaft to gea gearbo rbox x ⇒ page 146

1. Sealing rings

145


❑ Must Must be rene renewe wed d ifif re‐ re‐ moved ❑ 25 Nm

❑ Fit Fit behi behind nd the the flan flange ged d shafts Protected by copyright. Copying for p rivate or commercial commerc ial purposes, in part or in whole, is not permitted A. SEAT S.A does does not guarantee or accept any liability with ❑ Instal Installat lation ion posit position ion: : theunless authorised by SEAT S. A. respect to the correctness of information info rmation in this document. doc ument. Copyright by SEAT S.A. collar faces the spring

❑ Inst Instal alla lati tion on posi positi tion on:: conical side facing the differential casing ❑ Keep Keep the the fol follo lowi wing ng in po‐ sition: conical ring, ring, shim and pressure spring for flanged shaft when it is dismantled

❑ Repl Replac ace e afte afterr rem remov oval al ⇒ page 142

❑ Pull out ⇒ page 149 ❑ Press on on ⇒ page 150 ❑ Press ou out ⇒ page 150 ❑ Press on on ⇒ page 150 ❑ With With fina finall dri drive ve gear gear ❑ Press ou out ⇒ page 150 ❑ Press on on ⇒ page 150 ❑ Press ou out ⇒ page 150 ❑ Press on on ⇒ page 151

146



❑ for the differ different ential ial gear gear ❑ Dete Determ rmin ine e thi thick ckne ness ss ⇒ page 152 ❑ Repl Replac ace e afte afterr remo remova vall ⇒ page 143 ❑ Repairing ⇒ page 111 . 111 . ❑ Repairing ⇒ page 111 . 111 .

♦ Tighte Tightenin ning g plate plate - VW 402402♦ Tighte Tightenin ning g plate plate - VW 401401♦ Die - VW VW 40 408 AA♦ Die - VW VW 41 412♦ Tube Tube eleme element nt - VW VW 418 418 A♦ Thrus Thrustt plat plate e - 30-20 30-2055-


2. Differential:

147

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ♦ Drif Driftt slee sleeve ve - VW 455 455-♦ Separ Separati ation on cap cap - VW 472 472/2/2♦ Inla Inlay y sock socket et - 4040-21 21-♦ Tube Tube for for relea releasin sing g - 30-14 30-14-♦ Tube Tube ele eleme ment nt - 204 20400♦ Thru Thrust st pie piece ce - 3002 3002--


148


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ♦ Coun Counte terh rhol old d - 3067 3067-♦ Pipe ipe - 3259♦ Tape Tapered red roll roller er bear bearing ing pull pull‐‐ er - V.A.G 1582♦ Locki Locking ng devic device e - V.A.G V.A.G 1582/3♦ -1-1- Inter Interna nall pulle pullerr - Kukk Kukko o 21/7♦ -4-4- Coun Counter ter suppo support rt - Kukk Kukko o 22/2-

♦ Heat the inner ring of the roller bearing to 100 °C before fitting. ♦ Replace both conical roller bearings together. ♦ If tapered roller bearings, differential cage, gearbox housing or clutch housing is renewed, adjust differential ⇒ page 152 . .

A - Support bracket bracket , ex. -Kukko -Kukko 22/2B - Internal puller 46...58 mm , e.g. -Kukko 21/7-


2. Differential:

149


– Support the the gearbox gearbox casing by by fitting the tube tube - 32593259- directly underneath the bearing allotment.

Both tapered roller bearing inner races are pulled off the differ‐ ential cage in the same way.

– Support inner inner race on on opposite side side using installing installing sleeve VW 455- . Shoulder of installing sleeve - VW 455- faces towards differential cage.

Both tapered roller bearing inner races are pressed onto the dif‐ ferential cage in the same way.

B - Internal puller 46...58 mm , e.g. -Kukko 21/7Protected by copyright. Copying for private or commercial purposes, purposes, in part or in whole, is not permitted unless authorised SEAT S.A.red SEATroller S.A does not guarantee or accept any liability with – Clamp internal internal puller pulle r firmly under unby der tapered tape rolle r bearing bearin g outer respect to the correctness of information in this document. Copyright by SEAT S.A. race.

150



– Check hole for for spring pin in differential differential cage.

-A-

24.0 (short spring pin)

Removal ⇒ page 151

Installation ⇒ page 152

-A-A- and and -B-: -B-:

36.0 36.0 (lon (long g spr sprin ing g pin)

Removal ⇒ page 151


Cont Contin inuo uous us

36.0 36.0 (lon (long g spri spring ng Removal pin) ⇒ page 151


The spring pin is sheared off when pressing out. – Remove the remaining piece of sleeve sleeve from the differential differential casing.

– Drive clamping clamping sleeve -A- with a drift -B- diameter 5 mm out of bore-arrow-in the differential cage.

If there is no bore -arrow- in the differential cage, shear the clamp‐ Protected by copyright. Copying for private or commercial purposes, purp oses, in part or in whole, is not ing sleeve off ⇒permitted page 151 . authorise . unless authorised d 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.

2. Differential:

151


– Fit the complete complete assembly of of thrust washers washers lubricating with gear oil. – Fit the two large planetary gears and secure them (for example using the flanged axle). – Fit the small planetary planetary gears gears offset by 180° 180° and rotate rotate them inwards. – Press in differential differential pinion pinion pin -arrow -arrow A- to first planet planet pinion. – Place threaded threaded pieces -arrows -arrows B- in the sun gears. gears.

– Align hole in differential pinion pin with hole in differential cage. – Drive in the clamping clamping sleeve sleeve -1- with a drift drift to the dimension dimension -a- = 2.5 mm. •

The clamp clamping ing sleev sleeve e -1-1- must must not touch touch the clutch clutch housin housing. g.


152



♦ End End dime dimens nsio ion n plat plate eVW 385/17♦ Univer Universal sal dial dial gauge gauge brack brack‐‐ et - VW 387♦ Tighte Tightenin ning g plate plate - VW 402402♦ Tighte Tightenin ning g plate plate - VW 401401♦ Die - VW VW 40 408♦ Die - VW VW 41 412-


2. Differential:

153

León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 ♦ Thrus Thrustt plat plate e - 30-20 30-2055♦ Tube Tube for for relea releasin sing g - 30-14 30-14-♦ Tube Tube ele eleme ment nt - 204 20400♦ Pip Pipe - 3259♦ Torq Torque ue wren wrench ch V.A.G 1331♦ -1-1- Inter Interna nall pulle pullerr - Kukko Kukko 21/7♦ Dia Dial gauge


It is necessary to readjust the differential when the following com‐ ponents are renewed: ♦ Gear Gearbo box x hous housin ing g ♦ Clut Clutch ch hous housin ing g or or ♦ Diff Differ eren enti tial al cage cage or the ♦ Differen Differential tial tapered tapered roller roller bear bearing ing – Insert the outer outer ring of the the roller bearing bearing (crown (crown side) into the the gearbox casing

Inner and outer tapered roller bearing races are paired. Do not mix up.

154


León 2013 ➤ , León ST 2013 ➤ 6-speed manual gearbox 0AJ - Edition 11.2016 – Press tapered tapered roller roller bearing bearing outer race race (opposite (opposite gear wheel) with no shim into gearbox housing. – Insert differential differential in gearbox gearbox housing. housing. – Fit clutch housing housing and tighten tighten the 5 bolts. bolts.

– Fit the gauge gauge and set to “0” “0” with a pretension pretension of 1 mm. mm. A - 30 mm gauge gauge extension extension – Set dial gauge gauge to “0” with 1 mm preload preload for bearing. bearing. Protected copyright. Copying for private orup commercial purposes, inile partreading or in whole, is notmeas‐ – byMove the differential differential and down while wh readin g the permitted unless authorised authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with urement on the gauge and noting the results (for example: respect to the correctness of information in this document. Copyright by SEAT S.A.

1.50 mm raised).

The specified bearing preload is obtained by adding a constant value for preload (0.35 mm) to the reading obtained.

Average value value + Pressure value (const. value)

1.50 mm 0.35 mm

Shim thickness =

1.85 mm

– Remove clutch housing and and press out out tapered roller roller bearing bearing outer race -A-. B - Internal puller 46...58 mm , e.g. -Kukko 21/7 – Allocate the shim(s) shim(s) using ⇒ Electronic parts parts catalogue (ET‐ KA) . The existence of different thickness shims will enable the selec‐ tion of the correct thickness required. If the size of the shim required is larger than those listed in ⇒ Electronic spare parts catalogue (ETKA) install two shims amounting to the correct value. – Fit the shim shim of right right thickness (for (for this example example 1.85 mm) and reinsert the outer ring of the conical bearing into the clutch housing. – Fit clutch clutch housing housing and tighten bolts to specified specified torque torque setting.

♦ Gearbo Gearbox x housin housing g to clutch clutch housi housing ng ⇒ page 111

2. Differential:

155

D4B802C0BA3-6-Speed Manual Gearbox 0AJ

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