Service

Workshop Manual
Toledo 2013 ➤
5-speed manual gearbox 0A4
Edition 05.2016

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

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

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

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2016 Seat S.A D4B805362B6

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Filling quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Overview of the drive force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1 Fitting location overview - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Clutch drive mechanism: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Fitting location overview - clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Assembly overview - clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.5 Removing and installing bearing bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.6 Checking clutch master cylinder and clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . 19
1.7 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
19
1.8 Removing and installing over-centre
permitted unless spring
authorised by. SEAT
. . . .S.A.
. .SEAT
. . . S.A
. . does
. . .not
. .guarantee
. . . . . or. accept
. . . .any
. .liability
. . . .with
... 21
1.9 Removing and installing extension spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
respect to the correctness of information in this document. Copyright by SEAT S.A.

1.10 Clutch pedal: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.11 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.12 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.13 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.14 Removing and installing lines for clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.15 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.16 Clutch release assembly: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2 Coupling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.1 Exploded view - clutch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.1 Gear change mechanism installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.2 Assembly overview - gear lever knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.3 Exploded view - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.4 Removing and installing gear knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.5 Gearbox mechanism: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.6 Gear mechanism: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.7 Gear drive mechanism: adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.8 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2 Gearbox: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.3 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3 Engine/gearbox mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Contents i
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

3.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5 Gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.2 Draining and filling gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6 Installing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.1 Schematic overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.2 Exploded view - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.3 Assembly overview - cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . . . 94
7.4 Exploded view - gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . 95
7.5 Assembly overview - selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.6 Exploded view - shafts, differential, gear change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7.7 Assembly overview - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7.8 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.9 Seal for the selector shaft: replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.10 Repairing selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.11 Removing gearbox housing cover and 5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7.12 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.13 Installing cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
8 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
8.1 Assembly overview - gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . 125
8.2 Repairing the gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
8.3 Repairing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

1 Input shaft: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.1 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.2 Disassembly and assembly of the input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.3 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.4 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2.1 Assembly overview - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2.2 Input shaft: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.3 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3 Reverse gear shaft: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.1 Assembly overview - reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.2 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.1 Location overview - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.2 Renewing left oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2 Differential: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.1 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.2 Differential: assembly and disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.3 Adjusting differential . . . . .Copying
Protected by copyright. . . . . for
. .private
. . . .or. commercial
. . . . . . purposes,
. . . . . .in.part
. . or. in. .whole,
. . . is. not
................ 184
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
3 Adjustment chart . . to. the
respect . . correctness
. . . . . . of. .information
. . . . . .in .this
. .document.
. . . . . Copyright
. . . . . .by. SEAT
. . . S.A.
................... 187

ii Contents
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

00 – Technical data
1 Safety instructions
(ERL003108; Edition 05.2016)
⇒ “1.1 Safety precautions when working on vehicles with a start/
stop system”, page 1

1.1 Safety precautions when working on ve‐

hicles with a start/stop system

WARNING

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

hicles with the Start-Stop-System.
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
♦ When working on a vehicle, always deactivate the start/
respect to the correctness of information in this document. Copyright by SEAT S.A.

stop system. Switch off ignition.

♦ Switch on ignition only if it is necessary.

1. Safety instructions 1
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

2 Identification
⇒ “2.1 Gearbox identification”, page 2

2.1 Gearbox identification

Codes and production date -arrow 1- manual gearbox 0A4
-arrow 2-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Manual gearbox 0A4 -arrow 2- 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.

Engine code and manufacture date of gearbox

Example: PHB 22 01 4
I I I I
I I I I
Engine codes Day Month Year (2014)
of manufacture
Additional data identify the factory where the unit was built.

Note

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

2 Rep. gr.00 - Technical data

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

3 Technical data
⇒ “3.1 Allocation gearbox - engine”, page 3
⇒ “3.2 Filling quantity”, page 3
⇒ “3.3 Calculation of gear ratios”, page 3

3.1 Allocation gearbox - engine

Manual gearbox 5-speed 0A4
Engine codes QYD, QYC, PHB, PHY,SHY, SHZ,
RTE, RTF
Assignment Type Toledo
Engine 1.4 L TDI 66 kW
Gear ratio: Mechanism 61 : 18 = 3,389
Z2 : Z1
1. th gear 34 : 09 = 3,778
2. th gear 35 : 18 = 1,944
3. th gear 32 : 27 = 1,185
4. th gear 31: 38 = 0,816
5. th gear 30 : 48 = 0,625
6. th gear -
Reverse gear 36 : 20 X 18 : 09 = 3.600
I 2,118
total in top gear
Glean following data from ⇒ Electronic parts catalogue (ETKA) :
♦ Individual gear ratios
♦ Gearbox oil
♦ Clutch allocation

3.2 Filling quantity

Capacity of manual gearbox (gear‐ 2.0 litres
box completely dismantled)
Capacity of manual gearbox 1.8 litres
⇒ page 87 (gearbox partially dis‐
mantled)

3.3 Calculation of gear ratios

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Example: 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.
5. gear Final group
Driving gear ZG1 = 46 ZA1 = 24
Driven gear ZG2 = 33 ZA2 = 70

i = ZG2 : ZG1 1)
iG = Gear ratio = ZG2: ZG1= 33 : 46 = 0.717
iA = Final drive ratio = ZA2 : ZA1 = 70 : 24 = 2.917

3. Technical data 3
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

itotal = Overall ratio = iG x iA = 0.717 x 2.917 = 2.091

1) Z1 = Number of teeth of driving gear, Z2 = number of teeth of driving gear.

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.

4 Rep. gr.00 - Technical data

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

4 Overview of the drive force

Identification
-Arrows- point in direction of travel.

1 - Engine
2 - Coupling unit
3 - Manual gearbox
4 - Input shaft:
5 - Output shaft
6 - Differential:

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.

Ratio
-Arrows- point in direction of travel.

4. Overview of the drive force 5

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

I - 1. th gear
II - 2. th gear
III - 3. th gear
IV - 4. th gear
V - 5. gear
R - Reverse gear
A - Final group

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.

6 Rep. gr.00 - Technical data

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

5 Electrical components
⇒ “5.1 Fitting location overview - electrical components”,
page 7

5.1 Fitting location overview - electrical

components
⇒ “5.1.1 Fitting location overview - electrical components, manual
gearbox”, page 7
⇒ “5.1.2 Fitting location overview - electrical components, clutch
mechanism”, page 7

5.1.1 Fitting location overview - electrical

components, manual gearbox
Reversing light switch - F4- -arrow-.
Installation position: in the selector unit
Removing and installing reversing light switch - F4- ⇒ page 97

Gearbox neutral position sender - G701- -arrow-

Location: above oil filler plug.
Removing and installing gearbox neutral position sender - G701-
⇒ page 95 .

5.1.2 Fitting location overview - electrical

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

Clutch position sender - G476-of (-arrow

information A- and -arrow B-) by SEAT S.A.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness in this document. Copyright

Fitting location:
In engine compartment beneath supply hose -1- on clutch cylinder
-2- above line -3-.
Removal and installation of the sender for the clutch position -
G476- ⇒ page 19 .

5. Electrical components 7
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

6 Repair notes
⇒ “6.1 General repair notes”, page 8

6.1 General repair notes

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 of 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. They apply for this particular workshop manual.
Special tools
For a complete list of special tools used in this Workshop Manual
⇒ Workshop equipment and special tools .
Gearbox
♦ When installing the manual gearbox, ensure that the dowel
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
sleeves between the engine and gearbox areto positioned
respect cor‐
the correctness of information in this document. Copyright by SEAT S.A.
rectly.
♦ Clean contact surfaces when installing mounting brackets and
waxed components. The surfaces must be completely free
from wax or grease.
♦ Allocate bolts and other components using the ⇒ Electronic
parts catalogue (ETKA) .
♦ If the gearbox is repaired, fill with gear oil.
Gaskets and seals
Renew seals and gaskets.
After removing gaskets and seals, always inspect contact surface
of housing or shaft for burrs resulting from removal or for other
signs of damage.
♦ Thoroughly clean parting surfaces and apply sealant .
♦ Allocation ⇒ Electronic spare parts catalogue (ETKA)
♦ Before installing oil seal, half-fill space between sealing lips
with sealing grease - G 052 128 A1- -arrow-.
♦ The open side of the seals should face the liquid to be retained.
♦ Lightly oil the O-rings before installation, to prevent them from
being pressed together during installation.
Sealant
♦ Thoroughly clean joint surfaces on gearbox housing etc. be‐
fore applying sealant .
♦ Apply sealant evenly and not too thickly.
♦ Allocation ⇒ Electronic spare parts catalogue (ETKA)
♦ Breather holes must remain free of sealant .

8 Rep. gr.00 - Technical data

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Locking devices

♦ Replace safety rings.

♦ Do not overstretch retaining rings.
♦ The retaining rings must locate properly in the grooves.
♦ Renew spring pins. Installation position: the groove must face
parallel to the direction in which force is transferred.
Nuts and bolts
♦ Loosen and tighten bolts and securing nuts for covers and
housings diagonally.
♦ For delicate parts, e.g. the clutch press, do not tilt them and
always loosen the bolts gradually and in diagonal sequence
♦ Specified torques given are for unlubricated nuts, bolts and
screws.
♦ Renew self-locking nuts and bolts after each removal.
♦ Contact surfaces, bolts and nuts for all threaded joints must
be waxed when
Protected fittedCopying
by copyright. if necessary.
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
♦ Use thread taptoto
respect the remove
correctness remains
of informationof locking
in this fluid
document. frombyall
Copyright SEAT S.A.
threaded holes in which self-locking bolts are to be screwed.
Otherwise, there is a risk of the bolts breaking when next re‐
moved
♦ Check pitch of thread, to ensure correct thread chaser is used
to clean threads and to ensure the threads are not damaged.
Antifriction bearings
♦ Lubricate all bearings with gear oil before installing.
♦ Install the new conical roller bearings unchanged and without
greasing it.
♦ The needle bearings must be inserted with the engraved part
(thicker side of the plate) facing towards the installation tool.
♦ Conical roller bearings fitted into one same shaft must be re‐
placed together. They must have the same manufacturer.
♦ Use inductive heater - VAS 6414- to heat to approx. 100°C
before installing the inner bearing race.
♦ Do not confuse the outside and inside rings of the bearing with
the rings from other bearings of the same size. The bearings
come in matched pairs.

6. Repair notes 9
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Shims
♦ Check shim settings at various points, using a micrometer.
The various thicknesses make it possible to achieve the exact
shim thickness required.
♦ Check that it is not burred or damaged.
♦ Only fit shims in perfect state.

Synchromesh rings
♦ Do not mix them up. When reusing synchro-rings, always fit to
the same synchromeshed gear.
♦ Check for wear and renew if necessary.
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
flat spots (worn grooves).
♦ Make sure that the coating of coated synchro-rings is not dam‐
aged.
♦ If an intermediate ring -B- is installed, check the outer friction
surface -arrow 2- and inner friction surface -arrow 3- of this
intermediate ring for »scoring«, »signs of abnormal wear« and
»blue discolouration (due to overheating)«.
♦ Check the cone of the synchromeshed gear for »scoring« and
»signs of abnormal wear«.
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling.
Gears and synchro-hubs
♦ Before installing, clean and heat to 100°C (maximum) using
inductive heater - VAS 6414- .
♦ Observe installation position.
Mobile pinions
♦ After assembly, check synchromeshed gears for slight play, or
for freedom of movement.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Coupling unit 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.
♦ Ensure that the pressure plate does not cant: loosen and tight‐
en bolts diagonally and in several gradual stages.
♦ If the clutch has burnt out, thoroughly clean the clutch housing
as well as the friction surface of flywheel with a cloth to reduce
the smell of burnt linings.

10 Rep. gr.00 - Technical data

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

30 – Clutch
1 Clutch drive mechanism:
⇒ “1.1 Fitting location overview - clutch mechanism”, page 11
⇒ “1.2 Assembly overview - pedal cluster”, page 13
⇒ “1.3 Assembly overview - clutch hydraulics”, page 15
⇒ “1.4 Assembly overview - clutch release mechanism”,
page 18
⇒ “1.5 Removing and installing bearing bush”, page 19
⇒ “1.6 Checking clutch master cylinder and clutch slave cylinder”,
page 19
⇒ “1.7 Removing and installing clutch position sender G476 ”,
page 19
⇒ “1.8 Removing and installing over-centre spring”, page 21
⇒ “1.10 Clutch pedal: removing and installing”, page 23
⇒ “1.11 Removing and installing mounting bracket”, page 25
⇒ “1.12 Removing and installing clutch master cylinder”,
page 28
⇒ “1.13 Removing and installing clutch slave cylinder”,
page 29
⇒ “1.14 Removing and installing lines for clutch hydraulics”, page
32 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
⇒ “1.15 Bleeding clutch mechanism”, page 34
respect to the correctness of information in this document. Copyright by SEAT S.A.

⇒ “1.16 Clutch release assembly: repairs”, page 36

1.1 Fitting location overview - clutch mechanism

1. Clutch drive mechanism: 11

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

I-
⇒ “1.2 Assembly overview -
pedal cluster”, page 13
II -
⇒ “1.3.1 Assembly overview -
clutch hydraulics, left-hand
drive”, page 15
III -
⇒ “1.3.2 Assembly overview -
clutch hydraulics, right-hand
drive”, page 16

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.

12 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

1.2 Assembly overview - pedal cluster

1 - Clutch pedal
❑ removing and installing
⇒ page 23
❑ Cable must not be
greased
2 - Mounting bush
❑ removing and installing
⇒ page 19
❑ Cable must not be
greased
3 - Clutch master cylinder
❑ removing and installing
⇒ page 28
4 - Staple
❑ To remove pipe, pull out
clip
Protected to stop.Copying for private or commercial purposes, in part or in whole, is not
by copyright.
❑ respect
Cantobe driven in fully be‐
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
the correctness of information in this document. Copyright by SEAT S.A.
fore the line is installed
5 - Gasket
❑ Self-adhesive
❑ Renew after removing
the clutch master cylin‐
der
❑ Glue onto clutch master
cylinder
6 - Clutch position sender -
G476-
❑ Can be checked using
guided fault find-
ing of ⇒ Vehicle diag‐
nostic tester
❑ Allocation ⇒ Electronic
spare parts catalogue
(ETKA)
❑ removing and installing ⇒ page 19
7 - Pivot pin
❑ Renew after removing
❑ Cable must not be greased
8 - Bulkhead
❑ With studs for securing mounting bracket and master cylinder
9 - Drift sleeve
❑ For upper mounting hole in mounting bracket
❑ Bushes for lower mounting holes in mounting bracket are located in master cylinder
10 - Hexagonal nut
❑ For securing mounting bracket and clutch master cylinder to plenum chamber bulkhead
❑ 3 unit
❑ Self-locking
❑ Must be renewed if removed
❑ 25 Nm

1. Clutch drive mechanism: 13

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

11 - Crash bar
❑ Secured to module carrier
❑ Determine according to ⇒ Electronic parts catalogue (ETKA) .
12 - Hexagonal nut
❑ For crash bar on module carrier
❑ Must be renewed if removed
❑ 20 Nm
13 - Mounting bracket
❑ For clutch pedal
❑ removing and installing ⇒ page 25
❑ Using drift - VW 207- drive bushes for the studs used to fasten the mounting bracket onto the bulkhead,
into the holes in the mounting bracket
14 - Bump stop
15 - Over-centre spring or extension spring
❑ Grease support on mounting bracket
❑ For grease allocation, refer to ⇒ Electronic Parts Catalogue (ETKA)
❑ Fitted depending on design status
❑ Different versions available; for correct version refer to ⇒ Electronic parts catalogue (ETKA) .
❑ removing and installing with over-centre helper spring ⇒ page 21
❑ Removal and installation of extension spring are identical to removal and installation of over-centre spring
⇒ page 21
16 - Mounting bush
❑ Cable must not be greased
17 - Pivot pin
❑ For plunger/master cylinder
❑ Renew after removing
❑ Cable must not be greased
18 - Upper connector cover

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.

14 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

1.3 Assembly overview - clutch hydraulics

⇒ “1.3.1 Assembly overview - clutch hydraulics, left-hand drive”,
page 15
⇒ “1.3.2 Assembly overview - clutch hydraulics, right-hand drive”,
page 16

1.3.1 Assembly overview - clutch hydraulics, left-hand drive

1 - Hexagonal bolt
❑ 2x
❑ Tightening torque
⇒ page 18
2 - Bleeder valve
❑ Bleeding clutch mecha‐
nism ⇒ page 34
❑ Tightening torque
⇒ page 34
3 - Protective cap
4 - Supply hose
5 - Brake fluid reservoir
6 - Gaskets
❑ Must be fitted inProtected
supply by copyright. Copying for private or commercial purposes, in part or in whole, is not
hose 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.
7 - Clutch master cylinder
❑ removing and installing
⇒ page 28
8 - Staple
❑ To remove pipe, pull out
clip to stop.
❑ Can be driven in fully be‐
fore the line is installed
9 - Seals / O-rings
❑ Replace if damaged
❑ Pull onto line connection
❑ insert with brake fluid
❑ Whether a seal or an O-
ring is used depends on
the type of connection
⇒ page 32
❑ Allocation ⇒ Electronic spare parts catalogue (ETKA)
10 - Pipe/hose assembly
❑ Allocation ⇒ Electronic spare parts catalogue (ETKA)
❑ removing and installing ⇒ page 32
11 - Support
❑ For pipe/hose assembly
12 - Seals / O-rings
❑ Replace if damaged
❑ Pull onto line connection
❑ insert with brake fluid
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 32

1. Clutch drive mechanism: 15

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

❑ Allocation ⇒ Electronic spare parts catalogue (ETKA)

13 - Staple
❑ To remove pipe, pull out clip to stop.
❑ Can be driven in fully before the line is installed
14 - Clutch slave cylinder
❑ removing and installing ⇒ page 29

1.3.2 Assembly overview - clutch hydraulics, right-hand drive

1 - Hexagonal bolt
❑ 2x
❑ Tightening torque
⇒ page 18
2 - Clutch slave cylinder
❑ removing and installing
⇒ page 29
3 - Gearbox
4 - Pipe/hose assembly
❑ Allocation ⇒ Electronic
spare parts catalogue
(ETKA)
❑ removing and installing
⇒ page 32
5 - Seals / O-rings
❑ Replace if damaged
❑ Pull onto line connection
❑ insert with brake fluid
❑ Whether a seal or an O-
ring is used depends on
the type of connection
⇒ page 32
❑ Allocation ⇒ Electronic
spare parts catalogue
(ETKA)
6 - Brake fluid reservoir
7 - Gaskets
❑ Must be fitted in supply
hose
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.
8 - Supply hose
9 - Clutch master cylinder
❑ removing and installing ⇒ page 28
10 - Staple
❑ To remove pipe, pull out clip to stop.
❑ Can be driven in fully before the line is installed
11 - Support
❑ Secured to body
❑ For brake lines and pipe/hose line
12 - Support
❑ Secured to body

16 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

❑ For brake lines and pipe/hose line

13 - Brake lines
14 - Support
❑ Secured to body
❑ For pipe/hose assembly
15 - Seals / O-rings
❑ Replace if damaged
❑ Pull onto line connection
❑ insert with brake fluid
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 32
❑ Allocation ⇒ Electronic spare parts catalogue (ETKA)
16 - Staple 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
❑ To remove pipe,
respect pull
to the out clip
correctness to stop.in this document. Copyright by SEAT S.A.
of information
❑ Can be driven in fully before the line is installed
17 - Bleeder valve
❑ Bleeding clutch mechanism ⇒ page 34
❑ Tightening torque ⇒ page 34
18 - Protective cap

1. Clutch drive mechanism: 17

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

1.4 Assembly overview - clutch release mechanism

1 - Gearbox
2 - Ball head studs
❑ To remove and install,
remove gearbox
❑ Remove old grease
from contact surface of
clutch release lever
❑ Lubricate surface which
contacts ball head stud
with grease - G 000 100-
❑ 25 Nm
3 - Input shaft oil seal:
❑ renew ⇒ page 146
4 - Guide bushing
❑ To remove and install,
remove 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
❑ With vulcanised O-ring respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ If O-ring is damaged, re‐

new guide sleeve and
O-ring together
5 - Retaining spring
❑ To remove and install,
remove gearbox
❑ Secure to clutch release
lever
6 - Cylindrical bolt
❑ 20 Nm
7 - Clutch release lever:
❑ To remove and install,
remove gearbox
❑ Remove and install to‐
gether with release
bearing. ⇒ page 37
❑ Remove old grease
❑ Lubricate surface which contacts ball head stud with grease - G 000 100-
8 - Release bearing
❑ To remove and install, remove gearbox
❑ Do not wash out bearing; wipe clean only
❑ Replace collars that make a noise
❑ Removing from and inserting in clutch release lever ⇒ page 37
❑ Lubricate contact surface of release lever with MoS2 grease
9 - Hexagonal bolt
❑ 20 Nm
10 - Clutch slave cylinder
❑ removing and installing ⇒ page 29
11 - Plunger
12 - Assembly bolt
❑ Secures clutch release lever when gearbox is installed.

18 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

❑ Remove after gearbox has been installed.

❑ If assembly bolt is not available, an M 8 x 35 bolt can be used.

1.5 Removing and installing bearing bush

Removal:
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Compress catches -arrows- and take out pin -1- towards right
side.
– Pull the clutch pedal into the passenger compartment to stop.
– Remove over-centre spring/extension spring.

– Turn plunger of clutch master cylinder so that recesses -1- and

pin -2- are visible.
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
Recesses -1- and pinrespect
-2- are
to thefacing theof same
correctness direction.
information in this document. Copyright by SEAT S.A.

– Remove bearing bush -A- from recesses -1-.

Installation
– Turn plunger of clutch master cylinder so that recesses -1- and
pin -2- are visible.
Recesses -1- and pin -2- are facing the same direction.
– Fit and swivel bearing bush -A- into recesses -1-.
– Install over-centre spring/extension spring ⇒ page 21 , and
connect plunger/clutch master cylinder to clutch pedal.
– Use a new pivot pin.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .

1.6 Checking clutch master cylinder and

clutch slave cylinder
Carry out Guided fault finding using ⇒ Vehicle diagnostic
tester before you renew the clutch master cylinder with an as‐
sumed fault.

1.7 Removing and installing clutch position

sender - G476-
Special tools and workshop equipment required

1. Clutch drive mechanism: 19

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Hook - 3438-

Removal:
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
Left-hand guide
– Disconnect the engine control device with connected electrical
connector from its fixing on the bulkhead and lay to one side
⇒ Rep. gr. 23 ; Engine control device; Removing and installing
- J623- the engine control device
RHD
In some vehicles, the clutch master cylinder is located behind a
line for air conditioning system -arrow-.

An insulation mat is installed in conjunction with some engines.

Appearance may be different from that illustrated.
– Remove insulation mat. Note items -1 to 4-

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.

20 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Continuation for all vehicles

– Hang out the clutch position sender - G476- on master cylinder
-arrow A- and -arrow B-.
– Remove clutch position sender - G476- from master cylinder,
and disconnect connector.

Installation
– Fit clutch position sender - G476- all the way onto clutch mas‐
ter cylinder (electrical connector should be plugged in before‐
hand).
• Clutch position sender - G476- must clip in -arrow A-.
– To check, pull on clutch position sender - G476- -arrow B-.
– Disregard items -1, 2 and 3-.

– If present, attach the insulation mat

Protected by in the
copyright. order
Copying for-1, 2, or
private 3-commercial
around purposes, in part or in whole, is not
the lines. 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.
– Secure the insulation mat with the lock washer -4-.
Left-hand guide
– Attach the engine control device with connected electrical
connector to its fixing on the bulkhead ⇒ Rep. gr. 23 ; Engine
control device; Removing and installing - J623- the engine
control device

1.8 Removing and installing over-centre

spring
Removal:
– Move driver seat as far back as possible.
– Move steering wheel up as far as it will go, making use of full
range of steering column adjuster.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .

1. Clutch drive mechanism: 21

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Compress catches -arrows- and take out pivot pin -1- for
plunger/clutch master cylinder towards right side.
– Pull the clutch pedal into the passenger compartment to stop.
– Take out over-centre spring.
Installation
Installation is carried out in the reverse order. When installing,
note the following:

• Receptacle -arrow- for tip of clutch pedal must be vertical.

– Insert the over-centre spring on the side from underneath next
to the by
Protected plunger
copyright.of the master
Copying cylinder
for private or commercialand nextin part
purposes, to the clutch
or in whole, is not
pedal in the bracket -A- in the bearing bock.
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.

– Now position over-centre spring on mounting lug of clutch

pedal -arrow-.

Note

♦ The over-centre spring must be placed directly in the

recess-Arrow 1- in the mounting bracket, in order for it to be
placed correctly on the clutch pedal -Arrow 2-, (⇒ also previous
figure).
♦ Otherwise, it will not be possible to install the pivot pin -1- for
the plunger/clutch master cylinder (⇒ next figure).

22 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Press the clutch pedal until it is engaged and push through the
new pivot pin -1- for the plunger/clutch master cylinder to stop.
• The catches -Arrows- of the pivot pin -1- must engage.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .

1.9 Removing and installing extension

spring
Removal and installation of extension spring are identical to re‐
moval and installation of over-centre spring ⇒ page 21

1.10 Clutch pedal: removing and installing

⇒ “1.10.1 Removing and installing
Protected clutch
by copyright. Copyingpedal,
for privateLHD”,
or commercial purposes, in part or in whole, is not
page 23 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.
⇒ “1.10.2 Removing and installing clutch pedal, RHD”,
page 24

1.10.1 Removing and installing clutch pedal,

LHD
Removal:
– Move driver seat as far back as possible.
– Move steering wheel up as far as it will go, making use of full
range of steering column adjuster.
– Remove over-centre spring/extension spring ⇒ page 21 .
– If installed in area of mounting bracket: remove onboard sup‐
ply control unit - J519- (do not disconnect connector) ⇒
Electrical system; Rep. gr. 97 ; Control units; Removing and
installing onboard supply control unit - J519- .
Remove bearing shaft for clutch pedal, as follows:
-1- = 10 mm hexagon bit
• The pivot pin for the clutch pedal must be turned to the left to
stop, -direction of arrow-.
Locking devices -A- will be irreparably damaged.
– Move the clutch pedal slightly so that the pivot pin can be
pulled out.

1. Clutch drive mechanism: 23

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Installation
Installation is carried out in the reverse order. When installing,
note the following:
-1- = 10 mm hexagon bit
• Renew pivot pin after removing.
– Depress clutch pedal slightly and push new pivot pin through
to stop.
– Turn pivot pin to right to stop, -direction of arrow-.
• Locking devices -A- must audibly engage.
– Install over-centre spring/extension spring ⇒ page 21 .
– If removed beforehand: install onboard supply control unit -
J519- ⇒ Electrical system; Rep. gr. 97 ; Control units; onboard
supply control unit - J519- : removing and installing .

1.10.2 Removing and installing clutch pedal,

RHD
Removal:
– Remove mounting bracket ⇒ page 25 .
– Compress fasteners -arrows-, and pull pivot pin -1- for plunger/
clutch master cylinder off towards right (shown in illustration
with mounting bracket installed).
– Pull clutch pedal as far as stop.
– Remove over-centre spring/extension spring.

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.

Remove bearing shaft for clutch pedal, as follows:

-1- = 10 mm hexagon bit
• The pivot pin for the clutch pedal must be turned to the left to
stop, -direction of arrow-.
Locking devices -A- will be irreparably damaged.
– Move the clutch pedal slightly so that the pivot pin can be
pulled out.

24 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Installation
Installation is carried out in the reverse order. When installing,
note the following:
-1- = 10 mm hexagon bit
• Renew pivot pin after removing.
– Push new pivot pin through to stop.
– Turn pivot pin to right to stop, -direction of arrow-.
• Locking devices -A- must audibly engage.
– Install over-centre spring/extension spring ⇒ page 21 .
– Install mounting bracket ⇒ page 25 .

1.11 Removing and installing mounting

bracket
Special tools and workshop equipment required
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Hose clamps, up to 25 mm - 3094-
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.

♦ Torque wrench - V.A.G 1331-

♦ Sealing tool - T10249-

1. Clutch drive mechanism: 25

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Removal:
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
Left-hand guide
– Disconnect the engine control device with connected electrical
connector from its fixing on the bulkhead and lay to one side
⇒ Rep. gr. 23 ; Engine control device; Removing and installing
- J623- the engine control device
RHD
In some vehicles, the clutch master cylinder is located behind a
line for air conditioning system -arrow-.

An insulation mat is installed in conjunction with some engines.

Appearance may be different from that illustrated.
– Remove insulation mat. Note items -1 to 4-
Continuation for all vehicles
– Remove clutch position sender - G476- (without disconnecting
connector) from master cylinder ⇒ page 19 .

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

Note

♦ 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 the hose clamp - 3094- , the supply hose must
be returned to its original shape.

Caution

Risk of brake fluid escaping.

♦ During the following work, ensure that no brake fluid lands
on longitudinal member or gearbox. If this does happen,
clean thebyaffected
Protected areasforthoroughly.
copyright. Copying 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
♦ Lay arespect
lint-free
to the cloth under
correctness masterin this
of information cylinder.
document. Copyright by SEAT S.A.

26 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– In addition, for disconnecting, supply hose can be sealed with

sealing tool - T10249/1- .
– Pull off supply hose -2- (⇒ previous illustration).
– Pull clip for pipe/hose assembly -1- all way out (⇒ previous
illustration), and pull off pipe/hose assembly ⇒ page 31 .
– Seal openings.

– Unscrew nut -2-, detach crash bar -1-, and push to one side.
– Remove following components if installed in area of mounting
bracket:
Onboard supply control unit - J519- (do not disconnect connector)
⇒ Electrical system; Rep. gr. 97 ; Control units; Removing and
installing - J519- onboard supply control unit .
Footwell vent on driver side ⇒ Heating, air conditioning; Rep. gr.
87 ; Air duct; Assembly overview – air duct and air distribution in
passenger compartment .

– Remove securing nuts -1- and -2-.

– Detach mounting bracket -3-.
Installation
Installation is carried out in the reverse order. When installing,
note the following:
– Renew self-locking nuts and seal for clutch master cylinder
after removing.

– Fit crash bar -1-, and tighten nut -2-.

– If removed beforehand, reinstall following components:
Onboard supply control unit - J519- ⇒ Electrical system; Rep. gr.
97 ; Control units; Removing and installing - J519- onboard supply
control unit .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Footwell vent on driver side
permitted ⇒authorised
unless Heating, air S.A.
by SEAT conditioning;
SEAT S.A does Rep. gr. or accept any liability with
not guarantee
87 ; Air duct; Assemblyrespect
overview – air duct and air distribution in
to the correctness of information in this document. Copyright by SEAT S.A.

passenger compartment .
– Insert clutch position sender - G476- into master cylinder with
electrical connector connected. Push it in as far as stop
⇒ page 19 .

1. Clutch drive mechanism: 27

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Connect pipe/hose assembly -1- to connection ⇒ page 31 .

– Connect supply hose -2- at clutch master cylinder.
• After removing the hose clamp - 3094- , the supply hose must
be returned to its original shape.
Left-hand guide
– Attach the engine control device with connected electrical
connector to its fixing on the bulkhead ⇒ Rep. gr. 23 ; Engine
control device; Removing and installing - J623- the engine
control device

RHD
– If present, attach the insulation mat in the order -1, 2, 3- around
the lines.
– Secure the insulation mat with the lock washer -4-.
Continuation for all vehicles
– Bleeding clutch mechanism
Protected ⇒ page
by copyright. Copying 34 or commercial purposes, in part or in whole, is not
for private
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Install and/or connect battery
respect to the ⇒ ofElectrical
correctness system;
information in this Rep.
document. gr. by SEAT S.A.
Copyright
27 ; Battery; Disconnecting and connecting battery .
Tightening torques
♦ For securing mounting bracket to bulkhead ⇒ page 13
♦ Crash bar to module carrier ⇒ page 13

1.12 Removing and installing clutch master

cylinder

Note

♦ Carry out Guided fault finding 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.

Removal:
– Remove mounting bracket with master cylinder ⇒ page 25 .
– Compress fasteners on pivot pin -1- for plunger/clutch master
cylinder -arrows- (shown in illustration with mounting bracket
installed).

28 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Pull pivot pin for plunger/clutch master cylinder in direction of

-arrow A- out of clutch pedal.
Clutch master cylinder is engaged in mounting bracket by means
of catches -arrows B-.
– Release locking tabs -arrows B- from clutch master cylinder,
and forcefully pull clutch master cylinder out of mounting
bracket.
Illustration shows only 2 of 4 locking tabs -arrows B-.
Installation
Installation is carried out in the reverse order. When installing,
note the following:
• Renew pivot pin -arrow A- after removing.
• Pivot pin -arrow A- must audibly engage in clutch pedal.
– Ensure proper engagement by carefully pulling pivot pin.
– Engage clutch master cylinder in mounting bracket
-arrows B-.
– Ensure proper engagement by carefully pulling clutch master
cylinder.
– Install mounting bracket ⇒ page 25 .

1.13 Removing and installing clutch slave

cylinder
Special tools and workshop equipment required
♦ Hose clamps, up to 25 mm - 3094-

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.

♦ Torque wrench - V.A.G 1331-

1. Clutch drive mechanism: 29

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Removal:

Note

♦ Before replacing the clutch master 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.

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and connecting battery .
– Remove complete air filter housing if it prevents access to
slave cylinder ⇒ Rep. gr. 23 ; Air filter; Removing and installing
air filter housing .
– Release end-piece from gate selector cable ⇒ page 59 .
– Pull off clip -arrow 1- and remove relay lever together with ca‐
ble end-piece.
– Pull gear selector cable off pin.
– Detach securing clip -arrow 2- for gear selector cable from
gearbox selector lever -A-.
– Remove gearbox selector lever -A- by removing nut
-arrow 3-.

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.

– Remove cable support bracket -A-. To do so, unscrew bolts

-1-, -2- and -3-.
Bolt -1- is located below charge air cooler -arrow-.
– Then tie up gear selector cable and gate selector cable.

30 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Lay a lint-free cloth under slave cylinder.

– Release clip -A- with a screwdriver and disconnect pipe/hose
assembly -B- from connection.
– Pull pipe/hose assembly -B- out of clutch slave cylinder and
seal both openings.
– Remove bolts -arrows- and remove clutch slave cylinder.

Caution

Catch escaping brake fluid.

♦ Do not operate clutch pedal after pipe/hose assembly has
been disconnected.

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

– Fit clutch slave cylinder -A- and secure with bolts -arrows-.
– Connect pipe/hose assembly -B- ⇒ page 31 .

Disconnecting and connecting lines for clutch hydraulics

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

Note

♦ Instead of the seal -2- it is also possible to install an O-ring

⇒ page 32 .
♦ Renew seal -2- if damaged.

– Press pipe/hose assembly -1- into connection -4- so that clip

-3- snaps into place.
– Test pipe/hose line by tugging on it.

1. Clutch drive mechanism: 31

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Seals and O-rings for pipe/hose line or pipe line

Item Material of line connection
1 Line connection with circumferential groove
-arrow 1-
2 Line connection with shoulder -arrow 2-
3 Line connection with shoulder -arrow 2- and cir‐
cumferential groove -arrow 3-
• For line connection having circumferential groove -arrow 1-
and -arrow 3-, a seal or O-ring must be set there.
Assembling selector mechanism ⇒ page 59 .
Adjust selector mechanism ⇒ page 64 .
– Bleeding clutch mechanism ⇒ page 34
– If removed, install complete air filter housing ⇒ Rep. gr. 23 ;
Air filter, Removing and installing air filter housing .
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
Tightening torques
♦ Slave cylinder to gearbox ⇒ page 18

1.14 Removing and installing lines for clutch

hydraulics
Special tools and workshop equipment required
♦ Hose clamps, up to 25 mm - 3094-

Removal:
– Remove complete air filter housing if it prevents access to the
lines for clutch mechanism ⇒ Rep. gr. 23 ; Air filter; Removing
and installing air filter housing .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery tray and ⇒ Elec‐
trical system; Rep. gr. 27 ; Battery; Removing and installing
battery .
Left-hand guide 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
– Disconnect the engine controlrespect
deviceto thewith connected
correctness electrical
of information in this document. Copyright by SEAT S.A.
connector from its fixing on the bulkhead and lay to one side
⇒ Rep. gr. 23 ; Engine control device; Removing and installing
- J623- the engine control device

32 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

RHD
In some vehicles, the clutch master cylinder is located behind a
line for air conditioning system -arrow-.

An insulation mat is installed in conjunction with some engines.

Appearance may be different from that illustrated.
– Remove insulation mat. Note items -1 to 4-
Continuation for all vehicles

Caution

Risk of brake fluid escaping.

♦ During the following work, ensure that no brake fluid lands
on longitudinal member or gearbox. If this does happen,
clean the affected areas thoroughly.
♦ Lay a lint-free cloth under master cylinder.

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

Note

♦ 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 the hose clamp - 3094- , the supply hose must
be returned to its original shape.

– Pull clip for pipe/hose line -1- all the way out and remove pipe/
hose line.
– Seal openings.

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.

1. Clutch drive mechanism: 33

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Pull clip -A- all the way out and remove pipe/hose line -B-.
– Seal openings.

Note

-Arrows- can be disregarded.

– Seal off open lines and connections if necessary with clean

plugs from engine bung set - VAS 6122- .
– Move pipe/hose assembly clear and remove.
Installation
Installation is carried out in the reverse order. When installing,
note the following:

– Connect pipe/hose line -1- to master cylinder and slave cylin‐

der.
– Pull on pipe to check
Protected it isCopying
by copyright. secure.
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
• After removing the
respect hose
to the clamp
correctness - 3094-in, this
of information thedocument.
supplyCopyright
hose by -2-SEAT S.A.
must be returned to its original shape.
Left-hand guide
– Attach the engine control device with connected electrical
connector to its fixing on the bulkhead ⇒ Rep. gr. 23 ; Engine
control device; Removing and installing - J623- the engine
control device

RHD
– If present, attach the insulation mat in the order -1, 2, 3- around
the lines.
– Secure the insulation mat with the lock washer -4-.
Continuation for all vehicles
– Bleeding clutch mechanism ⇒ page 34
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery tray and ⇒ Elec‐
trical system; Rep. gr. 27 ; Battery; Removing and installing
battery .
– Install complete air filter housing ⇒ Rep. gr. 23 ; Air filter;
Removing and installing air filter housing .

1.15 Bleeding clutch mechanism

Special tools and workshop equipment required

34 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Brake filling and bleeding equipment - VAS 5234-

Note

♦ After carrying out work on the hydraulic clutch mechanism, the

system must be bled.
♦ When performing the following steps, make sure that no brake
fluid escapes onto the gearbox.
♦ Prefilling system is not necessary!
♦ Before bleeding, fill brake fluid reservoir with brake fluid up to
“max” marking.
♦ Clutch pedal is at rest position, is not being depressed..
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Brake fluid: allocation ⇒permitted
Electronic parts catalogue
unless authorised (ETKA)
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.

– Remove complete air filter housing if it prevents access to

bleeder valve (-arrow- figure below) ⇒ Rep. gr. 23 ; Air filter;
Removing and installing air filter housing .

1. Clutch drive mechanism: 35

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Pull clutch pedal back to rest position.

– Remove protective cap from the bleeder valve -arrow-.
– Connect brake filling and bleeding device .
– Connect bleeder hose to pressure hose of fluid collector bottle.
To bleed system, use 670 mm long bleed hose - V.A.G 1238/B3-
if necessary.
– Switch on brake filling and bleeding equipment .
• Working pressure: 2.0 bar, positive pressure
– Open bleeder valve.
– Allow about 100 cm3 of brake fluid to flow out.
– Close the bleed screw.
– Rapidly operate pedal from stop to stop 10 to 15 times.
– Open bleeder valve.
– Allow another 50 cm3 of brake fluid to flow out.
– Close the bleed screw.
– Switch off brake filling and bleeding equipment , and relieve
pressure completely from bleeding equipment.
– After finishing air bleeding, the clutch pedal must be activated
several times.
Tightening torque:
Component Nm
Bleeder valve 4,5

1.16 Clutch release assembly: repairs

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Lubricating permitted
grease - Gto 000
respect 100- of information in this document. Copyright by SEAT S.A.
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
the correctness

36 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

• Gearbox is removed.
Removing and installing release lever together with release bear‐
ing
– Unhook spring -arrow 1-
– Pull off release lever -arrow 2- and release bearing.
– Installation is carried out in reverse order.

Removing and fitting the clutch release bearing

– Press together locking lugs -arrows- on back of clutch release
lever and remove release bearing -A- from clutch release lev‐
er.
– Lubricate surface on clutch release lever which contacts ball-
head pin with grease - G 000 100- .
– To install, press release bearing -A- into clutch release lever
until retaining hooks -arrows- engage.
– Installing gearbox ⇒ page 67 .

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.

1. Clutch drive mechanism: 37

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

2 Coupling unit
⇒ “2.1 Exploded view - clutch unit”, page 38
⇒ “2.2 Removing and installing clutch”, page 41

2.1 Exploded view - clutch unit

⇒ “2.1.1 Assembly overview - clutch in conjunction with Sachs
dual-mass flywheel”, page 38
⇒ “2.1.2 Assembly overview - clutch in conjunction with LuK dual-
mass flywheel”, page 39
⇒ “2.1.3 Assembly overview - clutch in connection with simple
flywheel”, page 40

2.1.1 Assembly overview - clutch in conjunction with Sachs dual-mass flywheel

1 - Dual mass Flywheel:

❑ Removing and installing
⇒ Rep. gr. 13 ; Cylinder
block (gearbox end);
Assembly overview
Protected by copyright. - fly‐
Copying for private or commercial purposes, in part or in whole, is not
wheel unless
permitted . 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.
❑ check that the centring
pins are correctly seat‐
ed
❑ The clutch lining contact
surface must be free of
scores, oil and grease
2 - Clutch plate
❑ Allocation ⇒ Electronic
spare parts catalogue
(ETKA)
❑ removing and installing
⇒ page 41
❑ Always replace together
with the pressure plate
❑ Installation position
⇒ page 43
3 - Pressure plate
❑ With adjusting mecha‐
nism
❑ Only replace with the
clutch plate
❑ Allocation ⇒ Electronic
spare parts catalogue
(ETKA)
❑ removing and installing
⇒ page 41
❑ Checking ends of dia‐
phragm spring
⇒ page 43
❑ Check the elastic and riveted joints ⇒ page 43
4 - Plug
❑ Loosen and tighten in diagonal sequence
❑ Renew M 6 bolts after each removal.
❑ Allocation ⇒ Electronic parts catalogue (ETKA)

38 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

❑ M6: 12 Nm then turn 90° further

❑ M 7: 20 Nm

2.1.2 Assembly overview - clutch in conjunction with LuK dual-mass flywheel

1 - Flywheel
❑ Removing and installing
⇒ Rep. gr. 13 ; Cylinder
block (gearbox end);
Assembly overview - fly‐
wheel .
❑ check that the centring
pins are correctly seat‐
ed
❑ The clutch lining contact
surface must be free of
scores, oil and grease
2 - Clutch plate
❑ Allocation ⇒ Electronic
spare parts catalogue
(ETKA)
❑ removing and installing
⇒ page 44
❑ Always replace along
with SAC clutch press
❑ Installation position:
⇒ page 46 .
3 - SAC pressure plate
❑ SAC means “self-ad‐
justing clutch”
❑ Only replace with the
clutch plate
❑ Allocation ⇒ Electronic
spare parts catalogue
(ETKA)
❑ removing and installing
⇒ page 44
❑ Checking ends of dia‐
phragm spring
⇒ page 43
❑ Checking spring connections and riveted connections ⇒ page 43
4 - Plug
❑ Loosen and tighten in diagonal sequence
❑ Renew M 6 bolts after each removal.
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
❑ M6: 12 Nm then turn 90° further
❑ M 7: 20 Nm

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. Coupling unit 39
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

2.1.3 Assembly overview - clutch in connection with simple flywheel

1 - Flywheel
❑ Removing and installing
⇒ Rep. gr. 13 ; Cylinder
block (gearbox end);
Assembly overview - fly‐
wheel .
❑ check that the centring
pins are correctly seat‐
ed
❑ Keep contact surface for
clutch lining free of
grooves, oil and grease.
2 - Clutch plate
❑ Allocation ⇒ Electronic
spare parts catalogue
(ETKA)
❑ Centralising
⇒ page 48
3 - Pressure plate
❑ removing and installing
⇒ page 48
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Checking ends of dia‐
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
phragm spring respect to the correctness of information in this document. Copyright by SEAT S.A.
⇒ page 51
❑ Check the elastic and
riveted joints
⇒ page 51
4 - Plug
❑ Loosen and tighten in di‐
agonal sequence
❑ Renew M 6 bolts after
each removal.
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
❑ M6: 12 Nm then turn 90° further
❑ M 7: 20 Nm

40 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

2.2 Removing and installing clutch

⇒ “2.2.1 Removing and installing clutch in conjunction with Sachs
dual-mass flywheel”, page 41
⇒ “2.2.2 Removing and installing clutch in conjunction with LuK
dual-mass flywheel”, page 44
⇒ “2.2.3 Removing and installing clutch in connection with simple
flywheel”, page 48

2.2.1 Removing and installing clutch in conjunction with Sachs dual-mass fly‐
wheel

Special tools and workshop

equipment required
♦ Counterhold tool - 3067-
♦ Centring mandrel. - 3190 A-
♦ Torque wrench - V.A.G
1331-
♦ Grease for clutch plate
splines - G 000 100-

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.

Removal:
• Gearbox is removed.

2. Coupling unit 41
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Attach counterhold tool - 3067- before loosening bolts.

To prevent the pressure plate from becoming distorted during re‐
moval (causes clutch grab when driving off), always keep to the
following procedure when unbolting the pressure plate:

– Loosen all bolts in small steps and diagonally.

• While loosening the bolts, loosen the stop -2- with the pin
-1-.
– If that does not loosen the stop: push the pins against the dual-
mass flywheel.
– Remove clutch press and clutch plate.
Installation
Installation is carried out in the reverse order. When installing,
note the following:

Note

♦ Select correct clutch plate and pressure plate by checking en‐

gine code ⇒ Electronic spare parts catalogue (ETKA) .
♦ Clean input shaft splines and, on used clutch plate, hub
splines. Remove corrosion and apply only a very thin coat of
clutch plate spline grease - G 000 100- 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 the area of the clutch and parts of the engine facing the
gearbox in order to reduce the smell of burnt linings.
♦ Only blow out dual-mass flywheel with compressed air.
♦ Clutch plate linings must make full contact with flywheel and
friction surface of clutch pressure plate. Only then insert bolts.
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
♦ Tighten securing bolts in small steps diagonally in order not to
respect to the correctness of information in this document. Copyright by SEAT S.A.

damage centring holes of pressure plate and centring pins of

flywheel .
♦ Check whether dowel sleeves for centring engine/gearbox
have been fitted in cylinder block, insert if necessary.
♦ If the dowel sleeves are not fitted, this will lead to gear-change
problems, clutch malfunction and in some cases gearbox
noise (gears will make rattling noises).

42 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Clutch plate installation position

• The lettering “Getriebeseite” should face towards the gearbox.

Verification of the diaphragm spring

• Wear up to half the thickness of the diaphragm spring
-arrows- is permissible.

Check the elastic and riveted joints

I - Springs OK
• Slight kinking on the outside -arrows A- is normal on produc‐
tion parts.
II - Springs damaged
• Renew clutch pressure plate if springs are broken or badly
bent -arrow B-.

– Check that riveting -arrows B- is secure at all springs

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
-arrows
permitted unless A-. by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
authorised
respect to the correctness of information in this document. Copyright by SEAT S.A.
• Renew clutch pressure plate if riveting -arrows B- is loose.

2. Coupling unit 43
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Reverse position of counterhold tool - 3067- when installing.

– Insert the pressure plate in the centring pin.
– Use centring mandrel - 3190 A- to centralise clutch plate.
– Renew bolts after each removal.

Install pressure plate as follows so it is not deformed during in‐

stallation (leads to jolts when moving off):
– Make sure that stop pin (position setter) -arrow- can be moved
easily.
– Evenly screw in all bolts by hand until the bolt heads make
contact with the clutch pressure plate.
– Tighten all bolts diagonally and in small steps.
• The stop pin -arrow- should then lift away from the pressure
plate.
– Installing gearbox ⇒ page 77 .
Tightening torques
♦ Pressure plate on flywheel ⇒ page 38

2.2.2 Removing and installing clutch in conjunction with LuK dual-mass flywheel

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.

44 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Special tools and workshop

equipment required
♦ Counterhold tool - 3067-
♦ Centring mandrel. - 3190 A-
♦ Torque wrench - V.A.G
1331-
♦ Grease for clutch plate
splines - G 000 100-

Removal:
• Gearbox is removed.
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. Coupling unit 45
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Attach counterhold tool - 3067- before loosening bolts.

To prevent the pressure plate from becoming distorted during re‐
moval (causes clutch grab when driving off), always keep to the
following procedure when unbolting the pressure plate:
– Loosen all bolts in small steps and diagonally.
– Remove clutch press and clutch plate.
Installation
Installation is carried out in the reverse order. When installing,
note the following:

Note

♦ Select correct clutch plate and pressure plate by checking en‐

gine code ⇒ Electronic spare parts catalogue (ETKA) .
♦ Clean input shaft splines and, on used clutch plate, hub
splines. Remove corrosion and apply only a very thin coat of
clutch plate spline grease - G 000 100- 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 the area of the clutch and parts of the engine facing the
gearbox in order to reduce the smell of burnt linings.
♦ Only blow out dual-mass flywheel with compressed air.
♦ Clutch plate linings must make full contact with flywheel and
friction surface of clutch pressure plate. Only then insert bolts.
♦ 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 centring engine/gearbox
have been fitted in cylinder block, insert if necessary.
♦ If the dowel sleeves are not fitted, this will lead to gear-change
problems, clutch malfunction and in some cases gearbox
noise (gears will Protected
make rattling noises).
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.
Clutch plate installation position
• The lettering “Getriebeseite” should face towards the gearbox.

46 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Verification of the diaphragm spring

• Wear up to half the thickness of the diaphragm spring
-arrows- is permissible.

Note

Select correct clutch plate and pressure plate by checking engine

code ⇒ Electronic spare parts catalogue (ETKA) .

Checking springs and riveting

I - Springs OK
• Slight kinking on the outside -arrows A- is normal on produc‐
tion parts.
II - Springs damaged
• Renew clutch pressure plate if springs are broken or badly
bent -arrow B-.

Check the elastic and riveted joints

– Check that riveting -arrows B- is secure at all springs
-arrows A-.
• Renew clutch pressure plate if riveting -arrows B- is loose.

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. Coupling unit 47
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Checking position of adjustment mechanism (new pressure

plates only)
• Both edges -A- of the adjuster ring must be located between
the two notches -arrows B-.
• If the adjuster ring is in a different position on a new pressure
plate, the pressure plate and clutch plate must not be installed.
• The position of the adjuster ring can be outside the notches
on used clutches.

– Reverse position of counterhold tool - 3067- when installing.

– Insert the pressure plate in the centring pin.
– Use centring mandrel - 3190 A- to centralise clutch plate.
– Renew bolts after each removal.
Install pressure plate as follows so it is not deformed during in‐
stallation (leads to jolts when moving off):
– Evenly screw in all bolts by hand until the bolt heads make
contact with the clutch pressure plate.
– Tighten all bolts diagonally and in small steps.
– Installing gearbox ⇒ page 77 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Tightening torques
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.

♦ Pressure plate on flywheel ⇒ page 39

2.2.3 Removing and installing clutch in connection with simple flywheel

48 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Special tools and workshop

equipment required
♦ Counterhold tool - 3067-
♦ Centring mandrel. - 3190 A-
♦ Torque wrench -
V.A.G 1331-

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.

Removal:
• Gearbox is removed.

2. Coupling unit 49
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Attach counterhold tool - 3067- before loosening bolts.

To prevent the pressure plate from becoming distorted during re‐
moval (causes clutch grab when driving off), always keep to the
following procedure when unbolting the pressure plate:
– Loosen all bolts in small steps and diagonally.
– Remove clutch press and clutch plate.
Installation

Note

♦ Select correct clutch plate and pressure plate by checking en‐

gine code ⇒ Electronic spare parts catalogue (ETKA) .
♦ Clean input shaft splines and, on used clutch plate, hub
splines. Remove corrosion and apply only a very thin coat of
clutch plate spline grease - G 000 100- 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 the area of the clutch and parts of the engine facing the
gearbox in order to reduce the smell of burnt linings.
♦ Only blow out dual-mass flywheel with compressed air.
♦ Clutch plate linings must make full contact with flywheel and
friction surface of clutch pressure plate. Only then insert bolts.
♦ 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 centring engine/gearbox
have been fitted in cylinder block, insert if necessary.
♦ If the dowel sleeves are not fitted, this will lead to gear-change
problems, clutch malfunction and in some cases gearbox
noise (gears will make rattling noises).

• Installation location of clutch plate: labelling “gearbox end” or

spring cage is aligned to pressure plate.
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.

50 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Verification of the diaphragm spring

• Wear up to half the thickness of the diaphragm spring
-arrows- is permissible.

Check flexible connection and riveted unions

– Check spring connection between thrust plate and cover for
cracks and make sure rivet fastenings are seated tightly.
– If pressure plate has damaged
Protected springs
by copyright. Copyingorfor loose
private orrivet connec‐
commercial purposes, in part or in whole, is not
tions -arrows-, it must be renewed.
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.

Checking springs and riveting

I - Springs OK
• Slight kinking on the outside -arrows A- is normal on produc‐
tion parts.
II - Springs damaged
• Renew clutch pressure plate if springs are broken or badly
bent -arrow B-.
– Check spring connections -arrows A- for damage and make
sure rivet fastenings -arrows B- are seated tightly.
• Renew clutch pressure plate if spring connections are broken
or badly bent, or if riveting is loose.

– Check that riveting -arrows B- is secure at all springs

-arrows A-.
• Renew clutch pressure plate if riveting -arrow B- is loose.

2. Coupling unit 51
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Checking metal ring

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

– To centre the clutch plate the adapter - 3190 A- must be used.

– Renew bolts after each removal.
Install pressure plate as follows so it is not deformed during in‐
stallation (leads to jolts when moving off):
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

– Evenly screw in all bolts by hand until the bolt heads make
respect to the correctness of information in this document. Copyright by SEAT S.A.

contact with the clutch pressure plate.

– Tighten all bolts diagonally and in small steps.
– Installing gearbox ⇒ page 77 .
Tightening torques
♦ Pressure plate on flywheel ⇒ page 40

52 Rep. gr.30 - Clutch

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

34 – Controls, housing
1 Selector mechanism
⇒ “1.1 Gear change mechanism installation position”, page 53
⇒ “1.2 Assembly overview - gear lever knob and cover”,
page 55
⇒ “1.3 Exploded view - selector mechanism”, page 56
⇒ “1.4 Removing and installing gear knob”, page 57
⇒ “1.5 Gearbox mechanism: removing and fitting”, page 59
⇒ “1.6 Gear mechanism: repairing”, page 62
⇒ “1.7 Gear drive mechanism: adjustment”, page 64
⇒ “1.8 Checking selector mechanism”, page 66

1.1 Gear change mechanism installation

position

Note

♦ Disconnect battery before working on selector mechanism in

engine compartment ⇒ Electrical system; Rep. gr. 27 ; Bat‐
tery; Disconnecting and connecting battery .
♦ Gear selection mechanism: removing and fitting ⇒ page 59

-Arrow A- shows the gear selection movement and the gear se‐
lector cable.
-Arrow B- shows the gate selection movement and the gate se‐
lector cable

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.

1. Selector mechanism 53
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

A - Connection cable for gear

engagement
B - Selection control cable
C - Heat shield
❑ Remove before remov‐
ing selector mecha‐
nism.
1 - Selector lever
2 - Gate relay lever

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.

54 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

1.2 Assembly overview - gear lever knob and cover

1 - Gear lever knob

❑ With gaiter
❑ Gear knob and gaiter
cannot be separated
from one another
❑ Always replace together
❑ removing and installing
⇒ page 57
2 - Fastening clamp
❑ To secure gear knob on
selector lever
❑ Renew after removing
❑ Secure to gear knob us‐
ing hose clip pliers -
V.A.G 1275 A-
3 - Selector lever
4 - Cover of central console
❑ Combined with upper
part of centre console in
one part
❑ Separate for some ver‐
sions ⇒ General body
repairs, interior; Rep.
gr. 68 ; Covers, com‐
Protected bypartments and
copyright. Copying for trim;
private or commercial purposes, in part or in whole, is not
Centre console - As‐
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.
sembly overview .

1. Selector mechanism 55
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

1.3 Exploded view - selector mechanism

Note

♦ Lubricate bearing positions and sliding surfaces.

♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

1 - Selector shaft with cover

2 - Slide
3 - Gate relay lever
❑ Grease before installing
⇒ page 63 .
❑ Installation position
⇒ page 63
❑ After installing, adjust
selector mechanism
⇒ page 64
❑ Remove and install
⇒ page 60 relay lever
together with cable end-
piece
4 - Cable attachment
❑ To secure selection
control cable to relay
lever
❑ After installing, adjust
selector mechanism
⇒ page 64
❑ Do not mix up. Cable
end-pieces for gate se‐
lector cable to relay lev‐
er and gear selector ca‐
ble to gearbox selector
lever are different.
❑ Allocation ⇒ page 62
❑ Remove from relay lev‐
er ⇒ page 60
❑ Press onto relay lever
⇒ page 61
5 - Cable attachment Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ To secure selection permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
control cable to selection rod respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ After installing, adjust selector mechanism ⇒ page 64

❑ Do not mix up. Cable end-pieces for gate selector cable to relay lever and gear selector cable to gearbox
selector lever are different.
❑ Allocation ⇒ page 62
6 - Retainer washer
❑ Renew after removing
7 - Retainer washer
❑ Renew after removing
❑ Take care not to damage selector cables when removing.
8 - Selection control cable
❑ Connect to cable end-piece.

56 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

❑ Do not bend
❑ Installation position ⇒ page 53
9 - Gear change control cable
❑ Is located above gate selector cable
❑ Connect to cable end-piece.
❑ Do not bend
❑ Installation position ⇒ page 53
10 - Gear stick protective cover
11 - Gasket
❑ Between gear lever casing and vehicle underbody
❑ Renew after removing the selector housing.
❑ Self-adhesive
❑ Stick it onto the protective cover
12 - Hexagonal nut
❑ 4x
❑ M 6: 8 Nm
❑ M 8: 20 Nm
13 - Cable support bracket
❑ After installing, adjust selector mechanism ⇒ page 64
14 - Hexagonal bolt
❑ 3 unit
❑ for cable support bracket
❑ 20 Nm 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

15 - Collar
respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ 3 unit
❑ Cable support bracket mounting on gearbox
16 - Spacer
❑ 3 unit
17 - Hexagonal nut
❑ Tightening torque ⇒ page 97
18 - Selector lever
❑ Grease before installing ⇒ page 63 .
❑ Install so that gap in splines aligns with selector shaft ⇒ page 63
❑ Installation position ⇒ page 63
❑ After installing, adjust selector mechanism ⇒ page 64
19 - Oil seal
❑ renew ⇒ page 97
20 - Clip

1.4 Removing and installing gear knob

Special tools and workshop equipment required

1. Selector mechanism 57
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Hose clip pliers - V.A.G 1275 A-

♦ Lever - U30800-

Removal:
– Move back and forth -arrows- with the lever - U 30800- to prise
out the boot.

– Pull gaiter upwards, inside out over gear permitted

knob. unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

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

– Open clip -arrow- and pull off gear knob together with boot.
Installation
Installation is carried out in the reverse order. When installing,
note the following:
– Push gear knob together with boot onto gear lever as far as
stop.
– Attach gear knob with O-type clip -arrow- to gear lever. Use
hose clip pliers - V.A.G 1275 A- for this purpose.

58 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

1.5 Gearbox mechanism: removing and fit‐

ting
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Removal: 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
– Disconnect battery ⇒ Electrical system;
respect Rep. gr.
to the correctness 27 ; Battery;
of information in this document. Copyright by SEAT S.A.
Disconnecting and connecting battery .
– Remove gaiter with gear lever knob and any noise insulation
from centre console frame ⇒ page 57 .
– Remove the top part of the centre console together with the
mounting bracket of the centre console and the cup holder ⇒
General body repairs, interior; Rep. gr. 68 ; Covers, compart‐
ments and trim; Centre console - Assembly overview .
– Remove nuts for selector housing -arrows-.
– Lower selector housing.
– Remove the shock absorber of the selector housing⇒ General
body repairs, interior; Rep. gr. 68 ; Covers, compartments and
trim; Centre console - Assembly overview .
– Remove complete air filter housing if it is located over selector
mechanism ⇒ Rep. gr. 23 ; Air filter; Removing and installing
air filter .
– Pull gear selector cable off gearbox selector lever pin.
– Proceed as follows to remove gate selector cable from gate
relay lever:

Detach the fastening element from the selector cable

– Pull locking mechanism forward to stop in
-direction of arrow 1- and then lock by turning to left in
-direction of arrow 2-.
– Then push relay lever forwards (-direction of arrow 3-).
– Pull off clip -arrow 1- and remove relay lever together with ca‐
ble end-piece -arrow 2-.

1. Selector mechanism 59
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Remove cable support bracket -A-. To do so, unscrew bolts

-1-, -2- and -3-.
Bolt -1- is located below charge air cooler -arrow-.

Caution

Risk of damage to decoupling element at exhaust pipe.

♦ ⇒ Rep. gr. 26 ; Decontamination of exhaust gasses; As‐
sembly overview - Decontamination of exhaust gasses .

– Remove the heat shield under the selector mechanism ⇒

General body repairs, exterior; Rep. gr. 66 .
– Swing selector housing down and remove with selector ca‐
bles.

Removing relay lever together with cable end-piece

With gate relay lever removed: lever cable end-piece for gate se‐
lector cable off gate relay lever
– Insert a flat-blade screwdriver -A- between bush -B- and relay
lever.
Installation
Installation is carried out in the reverse order. When installing,
note the following:

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.

60 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Pushing cable end-piece for gate selector cable onto relay lever
• Relay lever has been removed
• Grease mounting pins for cable end-piece.
• Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
• Cable end-piece may be pressed only onto bush -arrow-.
• Cable end-piece must move freely on relay lever.
• Cable end-piece must be behind catch.
• Ensure proper engagement.
– Align selector housing parallel to body.
• Distance to body must be same on both sides.
Bolt gear stick housing

– Route cables -1- from selector mechanism -2- to gearbox as

follows:
•permitted
Cables
Protected must lie
by copyright. parallel
Copying to each
for private otherpurposes,
or commercial and mustin part not cross.
or in whole, is not
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
• Cables must be laid in the intended indentation in heat shield
respect to the correctness of information in this document. Copyright by SEAT S.A.

-3-.

On some equipment versions, cables and heat shield are held in

position by clip -A-.
– Secure gear selector cable with new securing clip to gearbox
selector lever.

1. Selector mechanism 61
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Installing relay lever together with cable end-piece

Note

Lubricate bearing positions and sliding surfaces. Allocate grease

using ⇒ Electronic parts catalogue (ETKA) .

– Insert relay lever together with cable end-piece -arrow 2- into

selector mechanism cover as far as stop.
– Press on clip -arrow 1-, making sure it engages securely.
– Insert the selector cable in the fastening element.
– Adjust selector mechanism ⇒ page 64 .
– Install centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Covers, compartments and trim; Centre console - As‐
sembly overview .
– Install gaiter with selector knob and, if present, noise insulation
⇒ page 57 .
– Install the heat shield under the selector mechanism ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66 .
– Install the exhaust system free of tension ⇒ Drive system;
Rep. gr. 26 ; Repairing exhaust system; Removing and in‐
stalling exhaust system components .
– If removed, install complete air filter housing ⇒ Rep. gr. 23 ;
Air filter; Removing and installing air filter housing .
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
Tightening torques
♦ Selector housing to body
⇒ “1.3 Exploded view - selector mechanism”, page 56
♦ Selector cable support bracket to gearbox
⇒ “1.3 Exploded view - selector mechanism”, page 56

1.6 Gear mechanism: repairing

Allocation of cable end-pieces
The holes on the cable securing elements have different diame‐
ters.
Cable end-piece for: Gap “a”
1. - Gear selector cable to gearbox selector lev‐ 8.5 mm
er
2 - Selection control cable to gate relay lever 10 mm

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.

62 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Installation position of the link rod/selector lever

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

Greasing the relay lever.

• Grease the shaft -A- of relay lever all over with great care
-arrows-, amount of grease: 0.2 grammes.
• Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

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.
Apply grease to gearbox selector lever
• Apply grease to guide rail -B- of gearbox selector lever in which
the relay lever engages, being especially careful when doing
so.
• Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

Fit the idler rod

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

1. Selector mechanism 63
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

1.7 Gear drive mechanism: adjustment

Special tools and workshop equipment required
♦ Locking pin - T10027 A-

ConditionsProtected
for thebyadjustment
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
• Moving parts of selector
respect mechanism
to the correctness and
of information elements
in this transferring
document. Copyright by SEAT S.A.

force must be in proper condition.

• Gear operation mechanism works smoothly.
• Gearbox, clutch and clutch mechanism in perfect condition.
• Gearbox must be in neutral.
– Remove the complete air cleaner housing if access to the
bracket -A- and the locking mechanism of the gear selector
cable and gate selector cable is obstructed ⇒ Rep. gr. 23 ;
Air cleaner; remove and install air cleaner housing .

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

lector cable end-pieces forward to stop -direction of arrow 1-
and then turn to left to lock -direction of arrow 2-.

64 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Lock selector shaft as follows:

– Press selector shaft down in -direction of arrow 1-.
– When pressing down the gearshift shaft turn angle lever -A- in
-direction of arrow 2- upwards and at the same time press it in
carefully until it locks into the gearshift shaft.

– Remove the boot and, if present, the noise insulation from the
centre console ⇒ page 57 .
Now secure gear lever as follows:
– Move the gear lever to neutral.
– Insert the Retention tool - T10027 A- into the hole -B- through
the hole -A-.

– Now turn locking mechanisms on gear selector cable and gate

selector cable end-pieces clockwise to stop
-direction of arrow-.
The spring returns the securing mechanism to the start position.

– Turn angled rod -A- back to original position in

-direction of arrow-
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.

1. Selector mechanism 65
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

• The angled rod -A- must be pressed out of selector housing to

stop and point to rear.

– Pull locking pin out of holes -A- and -B-.

– Install gaiter and, if necessary, damping ⇒ page 57 .
– Ensure that the selector shaft can move freely.
– If removed, install complete air filter housing ⇒ Rep. gr. 23 ;
Air filter; Removing and installing air filter housing .

1.8 Checking selector mechanism

• With gearbox in neutral, selector lever must be in selector lever
gate for 3rd and 4th gear.
– Engage clutch.
– Select all the gears several times. Pay particular attention to
the operation of the reverse gear locking mechanism.
– If the difficulty in engaging a gear persists after repeated at‐
tempts, repeat adjustment procedure of selector mechanism
⇒ page 64 .

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.

66 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

2 Gearbox: removing and fitting

⇒ “2.1 Removing gearbox”, page 67
⇒ “2.2 Installing gearbox”, page 77
⇒ “2.3 Specified torques for gearbox”, page 83

2.1 Removing gearbox

Special tools and workshop

equipment required
♦ Support tool - 10 - 222 A-
♦ Base plate - 10 - 222 A /1-
♦ 2 Adapter - 10-222 A /3-
♦ Shackle - 10-222 A /12- if
necessary.
♦ Gearbox support assembly
- 3282-
♦ Not required: bracket -
T10346-

♦ Adapters - T10540-

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. Gearbox: removing and fitting 67

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ 2 Adapter - 10 - 222 A /32-

♦ 2 Tensioning straps -
T10038-
♦ Template - T30020-
♦ Support elements for gear‐
box (determine when set‐
ting adjustment plate on
gearbox support - 3282- )
♦ Spindle from assembly tool
- 3066- or M8x105 mm bolt
♦ Thrust pad - T10148-

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.

68 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Engine/gearbox jack -
V.A.G 1383 A-
♦ Or engine and gearbox jack
- VAS 6931-
♦ Grease for clutch plate
splines - G 000 100-
♦ Allocate grease using ⇒
Electronic parts catalogue
(ETKA) .

– Remove complete air filter housing if it is located over gearbox

⇒ Rep. gr. 23 ; Air filter; Removing and installing air filter
housing .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery
Protected tray and
by copyright. ⇒ Elec‐
Copying for private or commercial purposes, in part or in whole, is not
trical system; Rep. gr. 27 ; Battery; Removing
permitted and installing
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
battery . respect to the correctness of information in this document. Copyright by SEAT S.A.

– If the lifting eyes of the engine for the support bracket - 10 -

222 A- are covered by cover or air filter, it must be removed
now ⇒ Rep. gr. 23 ; Air filter; Removing and installing air filter
housing .

2. Gearbox: removing and fitting 69

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Release end-piece from gate selector cable ⇒ page 59 .

– Pull off clip -arrow 1- and remove relay lever together with ca‐
ble end-piece.
– Detach securing clip -arrow 2- for gear selector cable from
gearbox selector lever -A-.
– Pull gear selector cable off pin.
– Remove gearbox selector lever -A- by removing nut
-arrow 3-.

– Remove cable support bracket -A-. To do so, unscrew bolts

-1-, -2- and -3-.
Bolt -1- is located below charge air cooler -arrow-.
– Then tie up gear selector cable and gate selector cable.

– Remove slave cylinder -arrows-, lay to side and secure. Do

not disconnect pipes.

Caution

Do not operate clutch pedal.

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.
– Remove bolts -1- and -2- securing gearbox -A- to engine.
Bolts -1- and -2- are located below charge air cooler -arrow-.

70 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Remove connector -arrow 1- from starter.

– Now, remove protective cap -arrow 2-, and disconnect line
from starter.
– Pull connector off reversing light switch - F4- -arrow 3-
– Then remove upper securing bolt from starter.

– Gearboxes for vehicles with start-stop system: pull connector

-arrow- from gearbox neutral position sender - G701- .

– Remove nut -arrow- and remove retainer for electrical lines.

– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter .
– Remove the foam and seal from the left and right of the top
edge of the mudguard ⇒ General body repairs, exterior; Rep.
gr. 50 ; Front wheel housing shell - assembly overview .
– Remove the crankcase ventilation hose ⇒ Rep. gr. 15 ; Cyl‐
inder head - assembly overview .
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10-222 A- , remove these now.

– Set up the support bracket - 10-222 A- behind bonnet support.

– Required special tools, workshop equipment and auxiliary
items:
♦ Adapters - T10540-
♦ Rack - 10 - 222 A /1-
♦ Adapters - 10 - 222 A /3-
♦ Adapters - 10 - 222 A /18-
♦ Adapters - 10 - 222 A /32-
♦ Support tool - T10038-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Rack feet - 10 - 222 A permitted
/1- areunless
not positioned on S.A.
authorised by SEAT longitudinal
SEAT S.A does mem‐
not guarantee or accept any liability with
bers with their entire contact surface.
respect to the correctness of information in this document. Copyright by SEAT S.A.

2. Gearbox: removing and fitting 71

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Secure both feet - 10 - 222 A /1- with tensioning straps -

T10038- .
• Tensioning belts must be guided past bonnet hinge/body as
close as possible to bolted connection.

– Insert adapter - T10540/1- in eyelet -A- on rear left of engine.

Bracket -arrow- points towards engine.

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.

– Then, bolt together adapters - T10540/1- and -T10540/2- .

The two adapters only fit together in one position.
Tightening torque
♦ Bolt -arrow- for securing adapter - T10540/1- to adapter -
T10540/2- .
♦ 35 Nm
– Connect adapter - T10540- and adapter - 10 - 222 A /32- .
– Using adapter - 10 - 222 A /32- , connect lifting eye at front
right of engine to support bracket (⇒ illustration above).
– Preload tensioning strap - T10038- slightly (⇒ illustration
above).
– Put some force on the drive train using the spindles.

72 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

The right drive shaft will be removed in a later step.

– With the vehicle still standing on all four wheels, loosen the
front right-hand side flange bolt by a maximum of 90° -arrow-
so as not to damage the wheel bearing ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Repair front wheel suspension; Front
axle - assembly overview .
– Remove sound insulation from the bottom of the engine/gear‐
box unit ⇒ General body repairs, exterior; Rep. gr. 66 .
– Remove the front left-hand wheel housing shell ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing shell; front
wheel housing shell - assembly overview .
– Then remove all lines from gearbox.

Caution

Risk ofpermitted
damage toauthorised
decoupling
by SEATelement.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless 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.
♦ ⇒ Rep. gr. 26 ; Decontamination of exhaust gasses; As‐
sembly overview - Decontamination of exhaust gasses .

– Disconnect the exhaust system behind the particle filter ⇒

Drive system; Rep. gr. 26 ; Repairing exhaust system; Re‐
moving and installing exhaust system components .

– Remove pendulum support -A- from the gearbox -arrows- and

the subframe -B- ⇒ Rep. gr. 10 ; Installing and removing en‐
gine; assembly mountings .

– Remove coupling rod -1- from the stabiliser on both sides ⇒

Running gear, axles, steering; Rep. gr. 40 ; Subframe, stabil‐
iser and axle guide; Subframe, stabiliser and axle guide -
assembly overview .
– Press anti-roll bar upwards
– Remove left drive shaft from the gearbox and secure ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts;
Removing and installing drive shafts or ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Repairing drive shafts; Removing and
installing drive shafts with tripod hinge .

2. Gearbox: removing and fitting 73

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– If fitted, remove drive shaft heat shield -arrows- ⇒ Running

gear, axles, steering; Rep. gr. 40 ; Repair front wheel sus‐
pension; Front axle - assembly overview .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Repairing drive shafts; Removing and installing
drive shafts or ⇒ Running gear, axles, steering; Rep. gr. 40 ;
Repairing drive shafts; Removing and installing drive shafts
with tripod hinge .

– Remove bolt -arrow- for right flange shaft by screwing two

bolts into flange and counterholding flange shaft with a as‐
sembly lever.
– Remove flange shaft.

Note

♦ Before removing flange shaft, check oil seal for leaks. If oil seal
leaks, it must be renewed during installation ⇒ page 173 .
♦ If gear oil escapes during removal of the flange shaft: with by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised
gearbox and flange shaft installed, drain gear oilrespect
and totop it up
the correctness of information in this document. Copyright by SEAT S.A.
again ⇒ page 87 .

– Screw spindle -A- of assembly tool - 3066- into threaded piece

of differential.
– Insert thrust piece - T10148- and secure with nut -B-.

Note

♦ The thrust piece - T10148- is intended to protect the right oil

seal and the gearbox against dirt.
♦ Instead of the spindle -A-, an M8x105 mm bolt can be screwed
hand-tight into the threaded piece of the differential.

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

mounting.

74 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Lower the gearbox by about 35 mm to dimension -a-.

• Securing bolts -arrows- for gearbox bracket -A- must be ac‐
cessible.

– Remove gearbox bracket -A- -arrows-.

– Remove lower engine/gearbox connecting bolt -1-.

Note

Loosen engine/gearbox connecting bolt -3- and leave it installed

just hand-tight.

Set up engine and gearbox jack with gearbox support - 3282- ,

adjustment plate - T30020- and support elements as follows:
– Place adjustment plate - T30020- on gearbox support - 3282-
(adjustment plate only fits in one position).
– Align arms of gearbox support - 3282- according to holes in
adjustment plate.

– Screw in support elements -A- and -C- as shown on adjust‐

ment plate.

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. Gearbox: removing and fitting 75

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Position engine and gearbox jack under vehicle with arrow

-B- on adjustment plate (figure above) pointing in direction of
vehicle travel.
– Align adjustment plate parallel to gearbox and lock safety sup‐
port on gearbox.
– Remove lower engine/gearbox connecting bolts.
– When performing following steps, observe coolant hose for
exhaust gas recirculation cooler.

– Push the gearbox off the dowel sleeves and swing carefully
towards the subframe.

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.

– Tip gearbox forwards in -direction of arrow- by means of the

adjusting spindle of the gearbox support - 3282- .
– Have a second mechanic push engine towards front end
slightly if necessary.

– Carefully lower gearbox with engine and gearbox jack , while

making sure that oil seal -1- for right flange shaft is taken past
the pressure plate -arrow- without becoming damaged.

76 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Guide left flange shaft -B- past subframe -arrow- as shown.

Move engine and gearbox jack together with gearbox to the
front end.
– While lowering gearbox, change position of gearbox using
spindles on gearbox support - 3282- .

Note

When lowering gearbox, guide it past power assisted steering line

and past subframe.

– Observe coolant hoses and electrical wiring.

– If appropriate, re-insert right flange shaft and tighten counter‐

sunk bolt -arrow- to 25 Nm.

2.2 Installing permitted

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

Note

For required special tools, refer to procedure “Removing gearbox”

⇒ page 67 .

Observe the following table on the subject of “checking and top‐

ping up gear oil”.
“Checking and topping up gear oil”
»no« »yes« »yes«
Gearbox Original X
part
No oil loss X
Completely X
dismantled Before in‐
stalling
⇒ Item 3
(page 125)
Oil capacity
⇒ page 3
Partially X
dismantled After instal‐
• (Gear‐ ling
box ⇒
housing page 87
and
clutch
housing
were not
separa‐
ted.)

2. Gearbox: removing and fitting 77

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

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

adjustment plate points in direction of vehicle travel.
– Remove right flange shaft if gearbox is new or has been re‐
placed -arrow-.

Note

♦ Before removing flange shaft, check oil seal for leaks. If oil seal
leaks, it must be renewed during installation ⇒ page 173 .
♦ If gear oil escapes during removal of the flange shaft: with
gearbox and flange shaft installed, drain gear oil and top it up
again ⇒ page 87 .

– Screw spindle -A- of assembly tool - 3066- into threaded piece

of differential.
– Insert thrust piece - T10148- and secure with nut -B-.

Note

♦ The thrust piece - T10148- is intended to protect the right oil

seal and the gearbox against dirt.
♦ Instead of the spindle -A-, an M8x105 mm bolt can be screwed
hand-tight into the threaded piece of the differential.

– All threaded holes into which self-locking bolts are to be

screwed must be carefully cleaned of residual locking fluid us‐
ing a thread chaser.
– Renew self-locking nuts and bolts after each removal.
– Check whether dowel sleeves for centring engine/gearbox
have been fitted in cylinder block, insert if necessary.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
If the dowel sleeves are unless
permitted not fitted, this
authorised will S.A.
by SEAT lead to S.A
SEAT gear-change
does not guarantee or accept any liability with
problems, clutch malfunction and in some cases gearbox noise
respect to the correctness of information in this document. Copyright by SEAT S.A.

(gears will make rattling noises).

– Ensure that intermediate plate is correctly seated on engine.
– Clean splines of input shaft and apply a thin coat of grease -
G000 100- .
It must be possible to move the clutch plate from side to side on
the input shaft.
– Check whether dowel sleeves for centring engine/gearbox
have been fitted in cylinder block, insert if necessary.
Set up engine and gearbox jack with gearbox support - 3282- ,
adjustment plate - T30020- and support elements as follows:
– Place adjustment plate - T30020- on gearbox support - 3282-
(adjustment plate only fits in one position).
– Align arms of gearbox support - 3282- according to holes in
adjustment plate.

78 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Screw in support elements -A- and -C- as shown on adjust‐

ment plate.

– Position engine and gearbox jack under vehicle with arrow

-B- on adjustment plate (figure above) pointing in direction of
vehicle travel.
– Align adjustment plate parallel to gearbox and lock safety sup‐
port on gearbox.

Note

Pay attention to all pipes/hoses/wiring when installing the gear‐

box.

– Tip gearbox forwards in -direction of arrow- by means of the

adjusting spindle of the gearbox support - 3282- .
– Then carefully raise gearbox.
– Have a second mechanic push engine forwards slightly.

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.

– Carefully lift gearbox with engine and gearbox jack , while

making sure that oil seal -1- is taken past the pressure plate
-arrow- without becoming damaged.

2. Gearbox: removing and fitting 79

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Note

♦ On vehicles with hydraulic power steering, observe the power

steering line.
♦ Guide left flange shaft -B- past subframe -arrow-.

– Move gearbox into installation position using spindles of gear‐

box support - 3282- .
– Install lower engine/gearbox securing bolts ⇒ page 83 .
– After gearbox has been bolted to engine, remove engine and
gearbox jack and engine support - 3300 A- with support plate
- T10413- from gearbox.

– Re-insert right flange shaft and tighten countersunk bolt

-arrow- to specified torque ⇒ page 177

– Fit gearbox bracket -A- with new bolts -arrows- ⇒ page 84 .

– Moisten bonded rubber mounting of left assembly mounting
and upper section of gearbox bracket with assembly lubrica‐
tion oil ⇒ Electronic parts catalogue (ETKA) .
– Align engine and gearbox in installation position.

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

box mounting.
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.

80 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Install pendulum support -A- on the gearbox -arrows- and the

subframe -B- with new screws ⇒ Rep. gr. 10 ; Installing and
removing engine; assembly mountings .
– Do not remove support bracket - 10 - 222 A- until all bolts se‐
curing the assembly mounting have been tightened to speci‐
fied torque!

– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.

40 ; Repairing drive shafts; Removing and installing drive
shafts or ⇒ Running gear, axles, steering; Rep. gr. 40 ; Re‐
pairing drive shafts; Removing and installing drive shafts with
tripod hinge .
– If fitted, install drive shaft heat shield -arrows- ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Repair front wheel suspension;
Front axle - assembly overview .

– Attach coupling rod -1- to the stabiliser on both sides ⇒ Run‐

ning gear, axles, steering; Rep. gr. 40 ; Repair front wheel
suspension; Front axle - assembly overview .
– Assemble the exhaust system ⇒ Drive system; Rep. gr. 26 ;
Repairing exhaust system; Removing and installing exhaust
system components .

– Install bolts -1- and -2- for securing gearbox -A- to engine
⇒ page 83 .
Bolts -1- and -2- are located below charge air cooler -arrow-.

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. Gearbox: removing and fitting 81

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Push connector -arrow 3- onto reversing light switch - F4- .

– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter .
– Bolt wire -arrow 2- to the starter and attach a protective cap ⇒
Electrical system; Rep. gr. 27 ; starter .
– Push on starter connector -arrow 1-.
– Pay particular attention to the correct position of the vacuum
hose for the brake system. If necessary, install vacuum hose
⇒ Brake system; Rep. gr. 47 ; Brake servo/brake master cyl‐
inder .

– Gearboxes for vehicles with start-stop system: join connector

-arrow- to gearbox neutral position sender - G701- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Install clutch slave cylinder -arrows- ⇒ page
permitted unless 29 .by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
authorised
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Install cable support bracket -A-. To do so, tighten bolts -1-,

-2- and -3- ⇒ page 56 .
Bolt -1- is located below charge air cooler -arrow-.

82 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Install gearbox selector lever -A- ⇒ page 63 .

– Tighten hexagon nut -arrow 3- to specified torque
⇒ page 97 .
– Spread a small amount of grease on pin of gearbox selector
lever -A-.
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Attach gear selector cable to gearbox selector lever.
– Renew securing clip -arrow 2- each time after removing.
– Install relay lever together with cable end-piece ⇒ page 62 .
• Clip -arrow 1- secures the relay lever.
• Ensure proper engagement of clip.
– Connect gate selector cable with cable end-piece.
– Adjust selector mechanism ⇒ page 64 .
– Install the front wheel housing shell ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing shell; front wheel hous‐
ing shell - assembly overview .
– Install sound insulation at the bottom of the engine/gearbox
unit ⇒ General body repairs, exterior; Rep. gr. 66 .
– Install the foam and seal from the left and right of the top edge
of the mudguard ⇒ General body repairs, exterior; Rep. gr.
50 ; Front wheel housing shell - assembly overview .
– Install the crankcase ventilation hose ⇒ Rep. gr. 15 ; Cylinder
head - assembly overview .
– Fit the battery ⇒ Electrical system; Rep. gr. 27 ; Battery .
– Follow procedure after connecting battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
– Install engine cover panel or air filter ⇒ Rep. gr. 23 ; Air filter;
Removing and installing air filter housing .

2.3 Specified torques for gearbox

Item Plug Control unit Nm
1 M12 x 60 1 80
2 M12 x 60 1 80
3 M12 x 165 1 80
♦ Additionally, start‐
er to gearbox
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4authorised by SEAT
permitted unless M12 S.A. x 165
SEAT 1 or accept any liability80
S.A does not guarantee with
♦ Additionally,
respect to the correctness start‐
of information in this document. Copyright by SEAT S.A.
er to gearbox

5 M10 x 55 3 40
6 M12 x 60 1 80
Item -A- dowel sleeves for centring

2. Gearbox: removing and fitting 83

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

3 Engine/gearbox mountings
⇒ “3.1 Exploded view - assembly mountings”, page 84

3.1 Exploded view - assembly mountings

1 - Plug
❑ Must be renewed if re‐
moved
❑ Gearbox bracket to
gearbox mounting
❑ 40 Nm + 90°
2 - Plug
❑ Gearbox mounting to
body
❑ ⇒ Rep. gr. 10 ; Remov‐
ing and installing the en‐
gine; assembly mount‐
ings
3 - Gearbox console
❑ ⇒ Rep. gr. 10 ; Remov‐
ing and installing the en‐
gine; assembly mount‐
ings
4 - Gearbox console
5 - Plug
❑ Renew after removing
❑ Gearbox bracket to
gearbox
❑ 40 Nm + 90°
6 - Pendulum support
❑ ⇒ Rep. gr. 10 ; Remov‐
ing and installing the en‐
gine; assembly
authorised bymount‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless SEAT S.A. SEAT S.A does not guarantee or accept any liability with
ings
respect to the correctness of information in this document. Copyright by SEAT S.A.

7 - Plug
❑ Pendulum support to
gearbox
❑ ⇒ Rep. gr. 10 ; Removing and installing the engine; assembly mountings
8 - Plug
❑ Pendulum support to sub-frame
❑ ⇒ Rep. gr. 10 ; Removing and installing the engine; assembly mountings
9 - Engine mounting
❑ ⇒ Rep. gr. 10 ; Removing and installing the engine; assembly mountings
10 - Plug
❑ 4x
❑ Engine mounting to body
❑ ⇒ Rep. gr. 10 ; Removing and installing the engine; assembly mountings
11 - Plug
❑ Engine mounting to engine
❑ ⇒ Rep. gr. 10 ; Removing and installing the engine; assembly mountings

84 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

12 - Plug
❑ Engine mounting to engine
❑ ⇒ Rep. gr. 10 ; Removing and installing the engine; assembly mountings

Gearbox bracket -A- to gearbox

– Renew bolts.
– Screw in all bolts hand-tight.
– Tighten bolts to specified torque ⇒ Item 5 (page 84) .

Gearbox bracket to gearbox mounting

– Renew bolts.
– Hand-tighten all the bolts.
– Tighten bolt to specified torque ⇒ Item 1 (page 84) .

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.

3. Engine/gearbox mountings 85
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

4 Transporting gearbox
Special tools and workshop equipment required
♦ Gearbox suspension tool - 3336-

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

– Adjust support beam on sliding piece using locking pin

-arrow-.
Number of holesProtected
visibleby=copyright.
5. Copying for private or commercial purposes, in part or in whole, is not
– Lift gearboxpermitted
using workshop craneofand
to the correctness gearbox
information lifting tackle
in this document. Copyright- by SEAT S.A.
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect
3336- .
– Set gearbox aside, for example in a transport container.

86 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

5 Gearbox oil
⇒ “5.1 Checking gear oil level”, page 87
⇒ “5.2 Draining and filling gearbox oil”, page 87

5.1 Checking gear oil level

It is not possible to check the gear oil level by unscrewing the oil
filler plug.

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.
The angle of the engine/gearbox unit means the lower edge of
the fill hole -arrow 1- is below the oil level -arrow 2-.
The oil level in the gearbox can only be checked by completely
draining the gearbox oil and then refilling ⇒ page 87 .

5.2 Draining and filling gearbox oil

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

♦ Hose (approx. 600 m long, external diameter 10 mm) with fun‐

nel, commercially available.
Drain gear oil.
Gear oil ⇒ Electronic parts catalogue (ETKA)
– Remove complete air filter housing if it is located over selector
mechanism ⇒ Rep. gr. 23 ; Air filter; Removing and installing
air filter .
– Remove the noise insulation ⇒ Bodywork, exterior fitting work;
Rep. gr. 66 .

5. Gearbox oil 87
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Clean gearbox.

Caution

To drain gear oil, a pivot pin for the selector forks in the gearbox
must be removed.
To prevent the positions of the selector forks from being
changed, e.g. due to accidental operation of the selector mech‐
anism, the selector shaft must be locked in position.

Secure selector shaft as follows:

– Press selector shaft down in -direction of arrow 1-.
– When pressing down the gearshift shaft turn angle lever -A- in
-direction of arrow 2- upwards and at the same time press it in
carefully until it locks into the gearshift shaft.
• The selector shaft is now locked.

Use a clean container of around 3.0 litres to hold the gear oil.
– Drain gear oil by first removing oil drain plug -arrow 1- and then
pivot pin for selector forks -arrow 2-.
– Install pivot pin for selector forks -arrow 2- with a new O-ring
⇒ page 95 .

– Screw in oil drain plug -arrow 1- ⇒ Item 15 (page 126) .

– Now turn angled rod -A- back to original position
-direction of arrow- so that selector shaft can move again.
Filling with gear oil 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 oil drain plug is tightened to 35 Nm. respect to the correctness of information in this document. Copyright by SEAT S.A.

• The pivot pin for selector forks is installed with a new O-ring
⇒ page 95 .
Gearbox oil ⇒ Electronic parts catalogue (ETKA)
Top up gear oil in container to 1.8 ltr.

88 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Remove reversing light switch - F4- -arrow-.

– Connect hose (approx. 600 mm, outer diameter 10 mm) to a
normal funnel.
– Insert hose in fitting hole for reversing light switch - F4- (sec‐
ond mechanic) and fill gear oil.
– Install the reversing light switch - F4- -arrow- ⇒ page 97
again.
– Check operation of selector mechanism ⇒ page 66 .
– If removed, install complete air filter housing ⇒ Rep. gr. 23 ;
Air filter; Removing and installing air filter housing .
– Install noise insulation ⇒ General body repairs exterior; Rep.
gr. 66 .

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.

5. Gearbox oil 89
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

6 Installing to engine and gearbox sup‐

port
Special tools and workshop equipment required
♦ Support clamp - VW 313-

♦ Retaining plate - VW 309-

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.

♦ or support plate - VW 309 A-

♦ Gearbox support assembly - VW 353-

– Secure gearbox on gearbox support - VW 353- .

– Place below the collecting tray .

90 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

7 Dismantling and assembling gearbox

⇒ “7.1 Schematic overview - gearbox”, page 91
⇒ “7.2 Exploded view - gearbox”, page 93
⇒ “7.3 Assembly overview - cover for gearbox housing and 5th
gear”, page 94
⇒ “7.4 Exploded view - gearbox housing and selector mecha‐
nism”, page 95
⇒ “7.5 Assembly overview - selector unit”, page 97
⇒ “7.6 Exploded view - shafts, differential, gear change”,
page 98
⇒ “7.7 Assembly overview - selector forks”, page 98
⇒ “7.8 Repairing selector unit”,Protected
page 99 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
⇒ “7.9 Seal for the selector shaft: replacement”, page
respect to the correctness 101 in this document. Copyright by SEAT S.A.
of information

⇒ “7.10 Repairing selector forks”, page 102

⇒ “7.11 Removing gearbox housing cover and 5th gear”,
page 105
⇒ “7.12 Dismantling and assembling gearbox”, page 111
⇒ “7.13 Installing cover for gearbox housing and 5th gear”,
page 121

7.1 Schematic overview - gearbox

7. Dismantling and assembling gearbox 91

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

1 - 1. th gear
2 - 2. th gear
3 - 3. th gear
4 - 4. th gear
5 - 5. gear
6 - Gearbox housing cover
7 - Gearbox
8 - Selector mechanism
❑ (Gear change prongs)
9 - Reverse gear pinion
10 -Protected
clutchbyhousing
copyright. Copying for private or commercial purposes, in part or in whole, is not
11 - Input shaft:
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.

12 - Output shaft
13 - Differential:

92 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

7.2 Exploded view - gearbox

I-
⇒ “7.3 Assembly overview -
cover for gearbox housing and
5th gear”, page 94
II -
⇒ “7.4 Exploded view - gear‐
box housing and selector
mechanism”, page 95
II -
⇒ “7.5 Assembly overview - se‐
lector unit”, page 97
II -
⇒ “7.8 Repairing selector unit”,
page 99
II -
⇒ “7.9 Seal for the selector
shaft: replacement”,
page 101
III -
⇒ “7.6 Exploded view - shafts,
differential, gear change”,
page 98
III -
⇒ “7.7 Assembly overview - se‐
lector forks”, page 98
III -
⇒ “7.10 Repairing selector
forks”, page 102

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.

7. Dismantling and assembling gearbox 93

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

7.3 Assembly overview - cover for gearbox housing and 5th gear

1 - Plug
❑ 5x
❑ To secure the cover on
the gearbox casing
❑ 18 Nm
2 - Gearbox housing cover
❑ With magnet
⇒ page 95

Note

If gearbox housing cover is removed

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

check respect
oil level and top up with gear
permitted unless 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.
oil ⇒ page 87 .

3 - Gasket
4 - Plug
❑ Renew after removing
❑ Fitted section of bolt
head holds dished
spring washer in posi‐
tion
❑ Clean residual locking
fluid from threaded
holes for securing bolts
for synchro-hub and for
5th gear wheel with a
thread chaser. Other‐
wise bolts can break.
❑ 80 Nm + 90°
5 - Dished washer
❑ Installing ⇒ page 123
6 - Cylindrical bolt
❑ For mounting bearing pin on transmission housing
❑ 25 Nm
7 - Pivot pin
8 - 5th gear selector fork
❑ Disassembling and assembling ⇒ page 102
9 - Spring
❑ Version with bent ends.
❑ Installing ⇒ page 141
10 - Locking collar for 5th gear
❑ Installation position ⇒ page 141
❑ setting ⇒ page 124
11 - Locking pieces (3 off)
❑ Installation position ⇒ page 140
12 - Synchronising hub with 5th speed selector gear and synchro-ring
❑ Remove together with the gearbox housing ⇒ page 111
❑ Remove individually ⇒ page 105

94 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

❑ Disassembling and assembling ⇒ page 141

13 - Needle roller bearing
14 - 5th gear pinion
❑ Remove together with the gearbox housing ⇒ page 111
❑ Remove individually ⇒ page 105
❑ Installation position ⇒ page 121

Cover for gearbox housing with magnet -A-

Magnet can only be fitted in cover with notch -arrow-.
With the cover fitted, the magnet is held in place by the bolt for
pivot pins of the selector fork 5th gear.

7.4 Exploded view - gearbox housing and selector mechanism

1 - Countersunk bolt
❑ removing and installing
⇒ page 177
2 - Flange shaft with spring
❑ removing and installing
⇒ page 173
❑ Assembling
⇒ page 177
3 - Torx screw
❑ For reverse shaft sup‐
port
❑ Self-locking
❑ Renew after removing
❑ 25 Nm
4 - Torx screw
❑ For reverse shaft sup‐
port
❑ Self-locking
❑ Renew after removing
❑ 30 Nm
5 - O-ring
❑ Renew after removing
6 - Pivot pin
7 - Plug
❑ 25 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
8 - Plug 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.
❑ 25 Nm

7. Dismantling and assembling gearbox 95

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

9 - Cover plate
10 - Internal splined bolt
❑ For reverse shaft support
❑ Renew after removing
❑ 25 Nm
11 - Plug
❑ 6 Nm
12 - Gearbox neutral position sender - G701-
❑ For vehicles with start stop system
13 - Gearbox
❑ Pull off together with 5th gear ⇒ page 111
❑ Repairing ⇒ page 125
14 - clutch housing
❑ Repairing ⇒ page 125
15 - Hexagonal bolt
❑ Renew after removing
❑ 25 Nm + 90°
16 - Selector shaft with cover
❑ (Selector unit)
❑ Repairing ⇒ page 99
17 - Internal splined bolt
❑ 25 Nm

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.

96 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

7.5 Assembly overview - selector unit

1 - Selector unit
❑ Consists of selector
shaft and selector shaft
cover
❑ Components cannot be
separated from each
other
2 - Reversing light switch - F4-
❑ Lightly coat lug with
MoS2 grease
❑ 20 Nm
3 - Angled rod
❑ To adjust the gear se‐
lection mechanism
❑ Removal ⇒ page 100
❑ Insertion ⇒ page 100
4 - Gate relay lever
❑ Installation position
⇒ page 63
5 - Clip
6 - Oil seal
❑ renew ⇒ page 101
7 - Hexagonal nut
❑ Self-locking
❑ Renew after removing
❑ 23 Nm
8 - Selector lever Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Installing ⇒ page 63 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.
9 - Upper connector cover
❑ For gearbox breather
10 - Cover plate
11 - Staple
❑ Not installed in all gearboxes.

7. Dismantling and assembling gearbox 97

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

7.6 Exploded view - shafts, differential, gear change

1 - Differential:
❑ Disassembling and as‐
sembling ⇒ page 177
2 - Oil seal
❑ 4x
❑ Renew after removing
3 - Output shaft
❑ ⇒ page 148
4 - Reverse shaft support
❑ ⇒ page 166
5 - Reverse gear shaft:
❑ ⇒ page 166
6 - Input shaft:
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
❑ ⇒ page 134 respect to the correctness of information in this document. Copyright by SEAT S.A.

7 - Reverse gear prong

❑ Disassembling and as‐
sembling ⇒ page 102
❑ Installation position
⇒ page 111
8 - Torx screw
❑ 25 Nm
9 - Selector mechanism
❑ (Gear change prongs)
❑ Disassembling and as‐
sembling ⇒ page 102
10 - clutch housing
❑ Repairing ⇒ page 125
11 - Hexagonal nut
❑ 4x
❑ Renew after removing
❑ 25 Nm + 90°
12 - Flange shaft with spring
❑ removing and installing ⇒ page 173
❑ Assembling ⇒ page 177
13 - Countersunk bolt
❑ removing and installing ⇒ page 177

7.7 Assembly overview - selector forks

Note

♦ 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.
♦ Repairing selector forks ⇒ page 102

98 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

1 - 5th gear selector segment

❑ Identification
⇒ page 103
❑ After lock washer is in‐
stalled, selector seg‐
ment must still rotate
freely.
2 - Lock washer
❑ Renew after removing
❑ Removal ⇒ page 104
❑ Installing ⇒ page 104
3 - 5th gear selector fork
4 - Plug
❑ 25 Nm
5 - 5th gear selector jaw
6 - Ball socket
❑ 4x
❑ Removal ⇒ page 104
❑ Press inner race into
outer race ⇒ page 104
❑ Installing ⇒ page 105
7 - Gearbox prong unit with
strips
8 - 1st/2nd gear selection
group
❑ Identification
⇒ page 103
❑ After lock washer is in‐
stalled, segment must
still rotate freely
9 - 3rd/4th gear base strip
❑ Identification ⇒ page 103
❑ After lock washer is installed, segment must still rotate freely
10 - Sliding piece
11 - Spring
12 - Reverse gear
Protected by prong
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
13 - Support fortoreverse
respect gear
the correctness selectorin this
of information fork document. Copyright by SEAT S.A.

14 - Securing ring

7.8 Repairing selector unit

Special tools and workshop equipment required

7. Dismantling and assembling gearbox 99

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Tube element - T10203-

♦ Torque wrench - V.A.G 1331-

– Remove selector unit ⇒ page 95 .

Removing angled rod -A- from selector shaft cover
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove outer part
permitted ofauthorised
unless angledbyrod.
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.
– Carefully lever out angled rod with a screwdriver.

Pressing angled rod -A- into selector shaft cover

Installation position:
Marking -arrow- points to upper part of selector shaft.
– Install selector unit ⇒ page 95 .

100 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

7.9 Seal for the selector shaft: replacement

Special tools and workshop equipment required
♦ Tube element - VW 423-

♦ Torque wrench - V.A.G 1331-

♦ Sealing grease ⇒ Electronic parts catalogue (ETKA)

– Remove gearbox selector lever and gate relay lever
⇒ page 56 .
– Lever seal out using a screwdriver.
– Lightly oil outer circumference of new oil seal.
– Half fill the area between the sealing lip and dust lip -arrow-
with sealing grease .

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.

7. Dismantling and assembling gearbox 101

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Drive in oil seal using tube - VW 423- .

– Install gearbox selector lever and gate relay lever
⇒ page 56 .

7.10 Repairing selector forks

Special tools and workshop

equipment required
♦ Pressure plate - VW 402-
♦ Thrust pad - 3290/1-
♦ Assembly tool - 3301-
♦ Thrust pad - VW 431-
♦ Separation cap - VW 472/2-
♦ Press tool - 10 - 206-

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.

102 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Lever for releasing -

80-200-

♦ Assembly Mandril -
10-508-

♦ Support equipment -
2070-

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.

Identification of the gear

groups
Gap -a-
1 - 1st and 2nd gear se‐
lector segments = 11.4
mm
2 - 3rd and 4th gear se‐
lector segments = 7.7
mm
3 - 5th gear selection
base strip = 12.1 mm

7. Dismantling and assembling gearbox 103

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Remove the securing ring

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

Fit the securing ring

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

Note

After lock washer is installed, segment must still rotate freely

A - Socket spanner with handle, size 10

B - Protective jaw covers

Removing angular contactProtected

ball bearing
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.

Note

Do not bend the prongs when removing and fitting the ball bear‐
ings.

Pressing inner race -A- of angular contact ball bearing into outer
race
Inner race must engage in outer race.

104 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Pulling angular contact ball bearing into selector fork to stop

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

Selector forks with detent segments installed

Value -a- (mm)
1st/2nd gear selector fork 87,2 … 87,4
prong of 3rd/4th gear 93,6 … 93,8
Selector segment assignment ⇒ page 103 .

7.11 Removing gearbox housing cover and

5th gear
5. Installing gear and cover for gearbox housing ⇒ page 121

Note

♦ Follow the working procedure described below if only the 5th

gear has to be removed:
♦ If the gearbox housing has to be removed, please refer to the
procedure
⇒ “7.12 Dismantling and assembling gearbox”, page 111 .
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.

7. Dismantling and assembling gearbox 105

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Special tools and workshop

equipment required
♦ Retaining plate - VW 309-
♦ or support plate - VW 309
A-
♦ Gearbox support assembly
- VW 353-
♦ Drift - VW 295-
♦ Assembly sleeve - VW 244
B-
♦ e.g. hot-air blower - V.A.G
1416-
♦ Torque wrench - V.A.G
1331-
♦ -Zweiarmabzieher Kukko
210.1-
♦ -Stehbolzen M 8 x 100 mm-

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.

106 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Support bridge - 30-211A-

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

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.

7. Dismantling and assembling gearbox 107

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Support bridge - T10323-

♦ Assembly tool - 3253/7-
♦ Thrust pad - VW 433-
♦ Pressure plate - 40 - 105-
♦ Torque wrench - V.A.G
1332-

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.

– Remove clutch release lever and release bearing ⇒ page 36 .

• Bearings of input shaft and output shaft must not be damaged
when 5th gear is removed and installed.
• Therefore, following tools must be mounted for support at this
stage during attachment of gearbox to gearbox support - VW
353- :
Underneath input shaft:
♦ Support bridge - 30-211A-
♦ Thrust piece - 32 - 111-
♦ Thrust pad - T10030/4-
• The input shaft can be supported by the thrust piece - 32 - 111-
only at a later point.
Underneath bearing support for output shaft:
♦ Support bridge - T10323-
♦ Assembly tool - 3253/7-
♦ Thrust pad - VW 433-

108 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Secure gearbox on gearbox support - VW 353- .

– Unscrew the gearbox casing cover -arrow-.

– Check whether puller hooks - T10040/2A- can be inserted

correctly under 5th gear wheel.
Puller hooks - T10040/2A- cannot be inserted correctly.
-A- Removal of “synchro-hub
Puller hooks - T10040/2A- make for 5th gear”, “gear wheel
contact too soon with: for 5th gear” and “gearbox
♦ Gearbox housing wall housing” “together”
⇒ page 111
♦ Ribs in gearbox housing under
gear wheel

-B-
Puller hooks - T10040/2A- come Copying for private or commercial purposes, in part or in whole, is not
Protected by copyright.
into contact withpermitted
ribs inunless
gearbox
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
housing below gear wheel.
respect to the correctness of information in this document. Copyright by SEAT S.A.

Puller hooks - T10040/2A- cannot be inserted correctly.

5. 5th gear can be removed separately, ⇒ from ⇒ page 109

5. Remove gear separately

– Cover the openings with a cloth.
– Put shift fork -1- in Neutral position.
– Remove bolt -2- with selector fork for 5th gear.
– Then remove both bolts -arrows- for pivot pins.
– Extract the socket pins.
– Remove selector fork.
– The spring ring -3- and the locking collar -4-do not need to be
removed.

7. Dismantling and assembling gearbox 109

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Unscrew
screws -A- for synchronizer body and 5th gear pinion. To do
so, engage 5th gear -arrow 1- and 1st gear -arrow 2- and
-arrow 3-
.
– After engaging both gears, the input shaft and the layshaft are
locked. The two bolts can now be loosened.

Note

If the shafts are to be reused, carefully clean residual locking ma‐

terial out of threaded holes using a thread chaser.

Pull off synchro-hub for 5th gear together with locking collar and
locking pieces
Use puller - T10309- .

– First set half sleeve - T10309/1- between 5th gear wheel -A-
and support for selector fork for 5th gear -B-.
• Shell half - T10309/1- must be positioned underneath synchro-
ring.
– If necessary, half sleeve must be pressed to end position.
– Turn half sleeve - T10309/1- to opposite side
-direction of arrow-.

– Set threaded insert in half shell - T10309/3- .

– Now, fit second half sleeve - T10309/1- and place tube -
T10309/2- on assembly.
– Check the by
Protected synchronizer
copyright. Copyingbody forordamage
for private commercial after removing.
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
– Renew respect
synchro-ring.
to the correctness of information in this document. Copyright by SEAT S.A.

– Remove 5th gear synchromeshed gear with needle bearing.

110 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Pull off gear wheel for 5th gear. (Shown here on another gear‐
box.)
– First set up puller hooks -A-.
B - Pressure plate - 40 - 105-

Note

When pulling off gear wheel, ensure that hooks do not bend out‐
wards. 5. After pulling off 5th gear wheel, examine for damage.

⇒ “7.13 Installing cover for gearbox housing and 5th gear”,

page 121

7.12 Dismantling and assembling gearbox

Removing and installing gearbox housing cover, gearbox hous‐
ing, selector shaft with selector mechanism cover, input shaft,
output shaft, differential and selector mechanism

Special tools and workshop

equipment required
♦ Retaining plate - VW 309-
♦ or support plate - VW 309
A-
♦ Gearbox support assembly
- VW 353-
♦ Drift - VW 295-
♦ Assembly sleeve -
VW 244 B- 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
♦ e.g. hot-air blowerrespect
- V.A.G
to the correctness of information in this document. Copyright by SEAT S.A.
1416-
♦ Torque wrench -
V.A.G 1331-
♦ -Stehbolzen M 8 x 100 mm-

7. Dismantling and assembling gearbox 111

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Support bridge - 30-211A-

♦ Thrust piece - 32 - 111-
♦ Thrust piece from assembly
tool - T10030/4-
♦ Tube element - VW 416 B-
♦ Puller plate - T10408-
♦ Thrust pieces - T10408/2-
♦ Grips - T10408/3-
♦ Hexagon bolts M7 x 35 with
washers
♦ Puller - 2 Kukko 18/1-

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.

112 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Support bridge - T10323-

♦ Assembly tool - 3253/7-
♦ Thrust pad - VW 433-
♦ Torque wrench - V.A.G
1332-

Gearbox disassembly
– Remove clutch release lever, release bearing and guide
sleeve ⇒ page 36 . 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
• Bearings of input shaft andrespect
output shaft must not be damaged
to the correctness of information in this document. Copyright by SEAT S.A.

when 5th gear is removed and installed.

• Therefore, following tools must be mounted for support at this
stage during attachment of gearbox to gearbox support - VW
353- :
Underneath input shaft:
♦ Support bridge - 30-211A-
♦ Thrust piece - 32 - 111-
♦ Thrust pad - T10030/4-
– Secure bolt of support bridge - 30-211A- with lock nut -A-.
Underneath bearing support for output shaft:
♦ Support bridge - T10323-
♦ Assembly tool - 3253/7-
♦ Thrust pad - VW 433-

7. Dismantling and assembling gearbox 113

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Secure gearbox on gearbox support - VW 353- .

– Place below the collecting tray .
– Unscrew oil filler plug and oil drain plug.
– Drain gear oil.
– Unscrew the gearbox casing cover -arrow-.

Remove selector fork for 5th gear as follows:

– Cover the openings with a cloth.
– Put shift fork -1- in Neutral position.
– Remove bolt -2- with selector fork for 5th gear.
– Then remove both bolts -arrows- for pivot pins.
– Extract the socket pins.
– Remove selector fork.
– The spring ring -3- and the locking collar -4-do not need to be
removed.

– Remove bolts -A- for synchro-hub and gear wheel for 5th gear.
To do this, engage 5th gear -arrow 1- and 1st gear
-arrows 2- and -3-.
– After engaging both gears, the input shaft and the layshaft are
locked. The two bolts can now be loosened.

Note

If the shafts are to be reused, carefully clean residual locking ma‐

terial out of threaded holes using a thread chaser.

– Remove both bolts -arrows- for reverse shaft support bracket.

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.

114 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Now remove 3rd bolt -arrow- for reverse shaft support bracket.

– Gearboxes for vehicles with start-stop system: remove gear‐

box neutral position sender - G701- -arrow-.

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.

– Remove selector shaft with selector mechanism cover, placing

selector shaft in neutral position. Then remove the bolts
-arrows- and take the selector shaft out of the gearbox casing.

– Remove cover plate -A- and pivot pins -B- from underside of
gearbox.

7. Dismantling and assembling gearbox 115

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

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

bolts -B- for gearbox housing to clutch housing in area of dif‐
ferential.

– Remove bolts -A- from clutch housing side for securing clutch
housing to gearbox housing.

Note

Do not remove nuts -B- for output shaft bearing support.

– Remove both of the flanged shafts.

– Take out flange shafts together with springs, thrust washers
and tapered rings.

Pull off following components together with gearbox housing:

♦ Synchro-hub for 5th gear
♦ 5th gear pinion
• Both grips - T10408/3- must be secured on gear wheel for 5th
gear.
• The grips must always be positioned above the two housing
ribs, which are located opposite each other -arrows-.

Note

♦ There is a needle bearing beneath the gear wheel for 5th gear.
♦ Secure the grips so that the bearing does not come in contact
with the gear wheel for 5th gear when the gearbox housing is
pulled off. 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.

116 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Use puller plate - T10408- in conjunction with following special

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

– Attach puller - Kukko 18/1- -A-.

– Remove 5th gear synchro-hub, 5th gear wheel and gearbox
housing by alternately tightening spindles -A- - (approx. 12
turns).
– If necessary, heat 5th gear wheel slightly using hot air blower
- V.A.G 1416- , for example.

– Remove nuts -B- for output shaft bearing support.

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.

– Remove selector forks -A- together with selector plates.

– Unscrew bolt for reverse gear selector mechanism -B-.

7. Dismantling and assembling gearbox 117

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Remove reverse gear -A-, input shaft -B- and output shaft
-C- one after the other from clutch housing.
– Remove differential.
Assembling gearbox
– Fit the differential.

– Renew seals -arrows- for output shaft bearing mounting after

removal.

Note

The figure shows only 3 of the 4 sealing rings.

– Insert input shaft -1- and output shaft -2- together.

– Tighten nuts for output shaft bearing mounting.
– Place reverse gear wheel -3- on needle bearing in clutch
housing.
The groove -arrow- should face away from the clutch housing.
– Ensure that reverse shaft -4- is complete ⇒ page 167 ; do not
yet fit reverse shaft support to reverse shaft.
– Fit the reverse shaft into clutch housing.
– Clean all locking fluid away from all threaded holes in reverse
shaft support; a thread cutter may be used for this purpose.
– Install reverse shaft support.

– Attach reverse gear selector fork -1- with support for reverse
gear selector fork -2-, spring -3- and sliding piece -4-.

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.

118 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Installation position: reverse gear

– Screw in the gear selection mechanism of the reverse gear

-A-.
– Install the gear prong -B- along with the selector plates.
Reverse gear support pin -C- is located in front of selector rods.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Screw M8 x 100 mm studs -A- into reverse shaft support so
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

that shaft is aligned after gearbox housing is fitted.

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

– Align selector plates.

Note

The selector segments must be positioned in the grooves on the

locking collars.

– Apply sealant evenly to sealing surface of clutch housing.

– Fit gearbox housing.
Insert the bolts for reverse gear shaft support -arrow- as shown:
– Fit bolt -a-.
– Remove stud -A- (⇒ figure above).

– Install bolt -c-.

7. Dismantling and assembling gearbox 119

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Tightening sequence:
– Tighten bolt -a- (see illustration above).
– Tighten bolt -b-.
– Tighten bolt -c- (see illustration above).

– Install the bearing pin -arrow- for the gear prongs. To do this
align selector mechanism using a screwdriver so that the rel‐
evant pivot pin can be inserted.
– Apply sealant evenly to the sealing surface of the cover flap.
– Fit cover plate for selector shaft.

Fit the selection shaft with the cover as shown below:

– Set selector plates in neutral position.
– Apply sealant evenly to sealing surface of selector mechanism
cover.
– Move selector shaft to neutral.
– Insert the selector shaft so that selector finger -arrow- is en‐
gaged in selector plates.
– Install and secure selector shaft cover.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Gearbox for vehicles with start/stop system: install gearbox
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

neutral position sender - G701- -arrow- and tighten securing

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

bolt.

120 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Install both flange shafts with compression springs, thrust

washers and tapered rings ⇒ page 177 .
Tightening torques
♦ ⇒ “7.4 Exploded view - gearbox housing and selector mecha‐
nism”, page 95
♦ Nuts for output shaft bearing mounting
⇒ “7.6 Exploded view - shafts, differential, gear change”, page
98
♦ Flange shaft to gearbox (countersunk bolt)
⇒ “2.1 Assembly overview - differential”, page 177
5. Installing gear and cover for gearbox housing ⇒ page 121

7.13 Installing cover for gearbox housing and

5th gear
For special tools required, refer to procedure for “Removing gear‐
box housing cover and 5th gear” ⇒ page 105 .
• Ensure that support bridge - 30-211A- and support device -
T10323- are installed.
– Secure bolt of support bridge - 30-211A- with lock nut -A-.

Installation position of 5th gear wheel

The groove running round the gear wheel -arrow- faces to the
gearbox housing.

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.

7. Dismantling and assembling gearbox 121

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Pressing on gear wheel for 5th gear

Checking 5th gear synchro-ring

– Press synchro-ring onto cone of synchromeshed gear prior to
installing synchromeshed gear and synchro-ring for 5th gear.
Measure gap -a- with a feeler gauge:
Gap -a- Assembly level Wear limit
5. gear 1.1 ... 1.7 mm 0.5 mm
– Install 5th gear synchromeshed gear with needle bearing.
– Fit 5th gear synchro ring on the mobile pinion.
– If synchro-hub and locking collar for 5th gear are dismantled,
assemble before installing ⇒ page 141 .

Installation position 5th gear synchro-hub and locking collar

The pointed teeth of the locking collar -arrow 1- and the high
shoulder of the synchronising hub -arrow 2- face the gearbox
housing.
The synchro-hub supports -arrow 3- align with the cast locking
pieces of the 5th gear synchro-ring ( ⇒ page 122 , bottom).
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.

5th gear synchro-ring with cast locking pieces

– Cover all openings in gearbox housing with a cloth to prevent
foreign bodies from entering gearbox.

122 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Knock on 5th gear synchronising hub.

Note

When driving on, ensure clearance for synchro-ring.

– Loosen support for input shaft.

WARNING

Wear protective gloves!

Clean residual locking fluid from threaded holes for securing bolts
for synchro-hub and for 5th gear wheel with a thread chaser.
Otherwise there is a risk that the bolts will shear off.
– Screw in securing bolts for synchronising hub and 5th gear
wheel.

Installation position
Protected byof dished
copyright. springs
Copying fororsecuring
for private bolts for
commercial purposes, gear
in part or in whole, is not
wheel and permitted
synchro-hub for 5th
unless authorised gearS.A. SEAT S.A does not guarantee or accept any liability with
by SEAT
respect to the correctness of information in this document. Copyright by SEAT S.A.
The outer circumference -arrows- faces 5th gear.

– Tighten securing bolts -A- for synchro-hub and gear wheel for
5th gear. To do this, engage 5th gear -arrow 1- and 1st gear
-arrows 2- and -3-.
– After engaging both gears, the input shaft and the layshaft are
locked. The two bolts can now be tightened.
– Install 5th gear selector fork.

7. Dismantling and assembling gearbox 123

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Adjusting 5th gear

– 5. Select 5th gear. Loosen bolt -1-. Press locking collar and
selector jaw in direction of arrow. Then tighten bolt -1- to
25 Nm.
• Control measurement: Between the mobile sleeve and the
mobile pinion, a thickness gauge of 0.2 mm cannot be inser‐
ted. If necessary, repeat the adjustment process.
– 5. th gear disengagement. Locking collar must now be in the
neutral position. Synchro-ring must move freely.
– Shift through all gears.
– Fit the gearbox casing cover ⇒ page 94 .
– Install release bearing guide sleeve ⇒ page 18 .
– Install clutch release lever and release bearing ⇒ page 36 .
– Fill with gear oil ⇒ page 87
Tightening torques
♦ ⇒ “7.3 Assembly overview - cover for gearbox housing and 5th
gear”, page 94
♦ 5th gear selector jaw
⇒ “7.7 Assembly overview - selector forks”, page 98 .

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.

124 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

8 Gearbox housing, clutch housing

⇒ “8.1 Assembly overview - gearbox housing and clutch housing”,
page 125
⇒ “8.2 Repairing the gearbox housing”, page 127
⇒ “8.3 Repairing clutch housing”, page 132

8.1 Assembly overview - gearbox housing and clutch housing

1 - Gearbox
❑ Modified output shaft
roller bearing
❑ Determine according to
⇒ Electronic parts cata‐
logue (ETKA) .
❑ When renewing, ⇒ ad‐
justment overview
⇒ page 187
2 - Roller bearing
❑ From the secondary
shaft.
❑ Roller bearing without
retaining ring and roller
bearing with retaining
ring
❑ Identifying roller bearing
for output shaft in gear‐
box housing
⇒ page 128
❑ Removing and installing
roller bearing without
circlip ⇒ page 129 .
❑ Removing and installing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
roller bearing with circlip
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.
⇒ page 129 .
3 - Filler plug
❑ The oil level cannot be
checked by removing
the oil filler plug
❑ If the gearbox was dis‐
mantled, it must be filled
prior to installation
❑ Capacity of manual
gearbox (gearbox com‐
pletely dismantled)
♦ 2.0 litres
❑ Capacity of manual gearbox (gearbox partially dismantled) ⇒ page 87
♦ 1.8 litres
❑ 35 Nm
4 - Outer track, roller bearing
❑ From the secondary shaft.
❑ ⇒ page 151
❑ If replaced, adjust the output shaft ⇒ page 161
❑ Note different versions when adjusting ⇒ page 164

8. Gearbox housing, clutch housing 125

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

5 - Shim
❑ From the secondary shaft.
❑ Adjustment overview ⇒ page 187
6 - Shim
❑ For input shaft
❑ Adjustment overview ⇒ page 187
7 - Outer track, roller bearing
❑ For input shaft
❑ removing and installing ⇒ page 136
❑ If replaced, adjust the input shaft ⇒ page 141
8 - Outer track, roller bearing
❑ For input shaft
❑ removing and installing ⇒ page 136 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ If replaced, adjust the input shaft ⇒ page
permitted unless141
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.
9 - Needle bearing shell
❑ removing and installing ⇒ page 167
10 - Dowel sleeve
❑ 2x
11 - clutch housing
❑ When renewing, ⇒ adjustment overview ⇒ page 187
❑ Determine according to ⇒ Electronic parts catalogue (ETKA) .
12 - Guide bushing
❑ With input shaft seal and vulcanised O-ring
❑ To remove and install, remove gearbox
❑ Driving out oil seal ⇒ page 147 .
❑ Driving in oil seal ⇒ page 147
❑ Remove guide sleeve in order to renew oil seal
❑ If O-ring is damaged, renew guide sleeve and O-ring together
13 - Cylindrical bolt
❑ removing and installing ⇒ page 18
14 - Gasket ring with bushing
❑ Renew seal and sleeve together.
❑ renew ⇒ page 173
15 - Oil drain plug
❑ 35 Nm
16 - Outer track, roller bearing
❑ For the differential
❑ Pressing out and pressing in ⇒ page 177
❑ If replaced, adjust the differential ⇒ page 184
17 - Magnet
❑ Supported by the application surface of the housing
18 - Oil collector
❑ Installing oil collector in gearbox housing ⇒ page 127
19 - Outer track, roller bearing
❑ For the differential
❑ Pressing out and pressing in ⇒ page 177
❑ If replaced, adjust the differential ⇒ page 184

126 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

20 - Shim
❑ For the differential
❑ Adjustment chart ⇒ page 187
21 - Oil seal
❑ renew ⇒ page 173

8.2 Repairing the gearbox housing

⇒ “8.2.1 Identifying output shaft bearing in gearbox housing”,
page 127
⇒ “8.2.2 Removing and installing roller bearing without retaining
ring”, page 128
⇒ “8.2.3 Removing and installing roller bearing with retaining
ring”, page 129
Installing oil collector -A- in gearbox housing
– Insert oil collector in hole -arrow 1- and groove -arrow 2- si‐
multaneously.

8.2.1 Identifying output shaft bearing in gear‐

box housing
The following roller bearings for the output shaft are installed:
Roller bearing -1- without circlip
A - Gearbox housing with shoulder for outer ring
B - Outer ring for tapered roller bearing
Removing and installing roller bearing without circlip
⇒ page 128 .

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.

8. Gearbox housing, clutch housing 127

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Roller bearing -1- with circlip

A - Gearbox housing with groove for circlip
B - Circlip for tapered roller bearing
Removing and installing roller bearing with circlip ⇒ page 129 .

Note

Allocation of gearbox housing and roller bearing via ⇒ Electronic

Parts Catalogue (ETKA) .

8.2.2 Removing and installing roller bearing

without retaining ring
♦ Drift - VW295-

♦ Thrust pad - VW 447 H-

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.

128 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Thrust pad - VW 512-

Roller bearing without

circlip, driving out

Roller bearing without circlip, driving in onto stop

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

8.2.3 Removing and installing roller bearing with retaining ring

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.

8. Gearbox housing, clutch housing 129

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Special tools and workshop

equipment required
♦ Press die - VW407-
♦ Press die - VW412-
♦ Thrust bearing from assem‐
bly tool - 3301-
♦ Assembly tool - 3346-
♦ Tube - 30-14-
♦ Installing tool - 30-506B-

♦ Thrust plate - VW402-

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.

130 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Thrust block - VW442-

♦ Thrust block - 3051-

Roller bearing with cir‐

clip, removing

– When pulling out roller bearing -1-, press circlip -2- together
with pliers.

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.

8. Gearbox housing, clutch housing 131

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Roller bearing with circlip, pressing in

– Place gearbox housing on tube - 30-14- in area of roller bear‐
ing.
– Press together circlip and press in roller bearing until circlip
engages in surrounding groove.

8.3 Repairing clutch housing

♦ Puller - VW 228 B- (not re‐

quired with thisby gearbox)
Protected 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
♦ Drift - VW 222
respectA- (not
to the re‐ of information in this document. Copyright by SEAT S.A.
correctness
quired with this gearbox)
♦ Assembly device - 3066-
(Spindle from assembly de‐
vice)
♦ Thrust pad - 3124-
♦ Universal tool - VW 771-
♦ Puller hooks - VW 771/37-

132 Rep. gr.34 - Controls, housing

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Thrust pad - T10148-

Pulling out sleeve and

seal
A shoulder is located on
inside diameter of
sleeve.
– Place puller hooks -
VW 771/37- behind
shoulder in sleeve.
– When extracting, the
puller hook -
VW 771/37- must be
pressed tightly into
the sleeve.

Pulling in sleeve and seal

– Clean seat for seal in gearbox.
– Screw spindle -A- of assembly tool - 3066- into threaded piece
of differential.
– Pull sleeve in to stop using thrust piece - T10148- by turning
nut -B-.

Note

With gearbox dismantled, press sleeve in to stop using thrust

piece - T10148- .

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.

8. Gearbox housing, clutch housing 133

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

35 – Gears, shafts
1 Input shaft:
⇒ “1.1 Assembly overview - input shaft”, page 134
⇒ “1.2 Disassembly and assembly of the input shaft”, page 136
⇒ “1.3 Adjusting input shaft”, page 141
⇒ “1.4 Renewing input shaft seal”, page 146

1.1 Assembly overview - input shaft

Note

♦ When installing new sliding gears or a new input shaft, all details of the ⇒ Electronic spare parts catalogue
ETKA and technical data must be observed.
♦ The input shaft must be re-adjusted if the position of tapered roller bearings is affected when renewing parts.
Consult adjustment chart . ⇒ page 187

1 - clutch housing
2 - Outer track, roller bearing
❑ Pressing out
⇒ page 137
❑ Insertion ⇒ page 138
3 - Inner ring and roller bearing
unit
❑ Pressing out
⇒ page 138
❑ Insertion ⇒ page 138
4 - Input shaft:
❑ setting ⇒ page 141 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
5 - 3rd gear wheel respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Fitting location: collar

faces 4th gear
❑ Pressing out
⇒ page 139
❑ Insertion ⇒ page 139
6 - Securing ring
❑ Renew after removing
7 - 4th gear wheel
❑ Pressing off with ta‐
pered roller bearing out‐
er race and sleeve
⇒ page 138
❑ Insertion ⇒ page 139
❑ Collar faces 3rd gear
8 - Inner ring and roller bearing
unit
❑ Pressing off with 4th
gear wheel and sleeve
⇒ page 138 .

134 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

❑ Insertion ⇒ page 139

9 - Thrust washer
10 - Outer track, roller bearing
❑ Pressing out ⇒ page 140
❑ Insertion ⇒ page 140
11 - Shim
❑ Determine thickness ⇒ page 141
12 - Gearbox
13 - Drift sleeve
❑ For needle bearing
❑ Press off with gear wheel for 4th gear and tapered roller bearing inner race ⇒ page 138
❑ Insertion ⇒ page 140
❑ Fit thrust washer before installing
14 - Needle roller bearing
15 - Mobile pinion of 5th gear
16 - Synchromesh ring of 5th gear:
❑ With cast locking pieces ⇒ page 122
❑ Check for wear ⇒ page 122
17 - Spring
❑ Installation position ⇒ page 141 and ⇒ page 141
18 - Locking pieces (3 off)
❑ Installation position ⇒ page 140
19 - Synchro-hub for 5th gear
❑ Pulling off, from ⇒ page 105 .
20 - Locking collar for 5th gear
❑ Pullingpermitted
off with
Protected bysynchro-hub
copyright. Copying for 5th gear,
for private frompurposes,
or commercial ⇒ page 105
in part or in. whole, is not
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
21 - Dished washer
respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Installation position ⇒ page 123

22 - Plug
❑ Renew after removing
❑ Fitted section of bolt head holds dished spring in position ⇒ page 123
❑ removing and installing ⇒ page 105
❑ Tightening torque ⇒ page 94

1. Input shaft: 135

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

1.2 Disassembly and assembly of the input shaft

Special tools and workshop

equipment required
♦ Press die - VW 407-
♦ Pressure disk - VW 447 H-
♦ Press die - VW 412-
♦ Tube element - VW 422-
♦ Pressure plate - VW 401-
♦ Pressure plate - VW 402-
♦ Press die - VW 408 A-

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.

136 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Tube element - VW 421-

♦ Thrust pad - VW 454-
♦ Pressure disk - VW 447 i-
♦ Pressure disk - VW 510-
♦ Drift sleeve - 41-501-
♦ -3- Splitter - Kukko 17/1-

Pressing out tapered roller bearing outer race

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.

1. Input shaft: 137

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Pressing in tapered roller bearing outer race

Pressing off tapered roller bearing inner race

A - Splitter -Kukko 17/1-

Inserting the inner ring of the roller bearing by pressure

Pressing off gear wheel for 4th gear with tapered roller bearing
and sleeve

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.

138 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Pressing off 3rd gear wheel

Pressing on gear wheel for 3rd gear

Pressing on 4th gear wheel

Shoulder faces 3rd gear 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.

Inserting the inner ring of the roller bearing by pressure

1. Input shaft: 139

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Pressing on sleeve for needle bearing

Pressing out tapered roller bearing outer race

Pressing in tapered roller bearing outer race

– Install with shim after adjusting input shaft.

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.

5th gear synchromesh

1- Spring rings for locking pieces
2- Locking collar with 3 recesses -arrows A- for the locking
pieces -item 4-
3- Synchromesh
4- Installation position: the recess -arrow B- points to the teeth
terminating in the end of the sliding sleeve -2-

140 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Assembling 5th gear locking collar/synchro-hub

– Slide locking collar over synchronising hub.
Pointed teeth -A- and shoulder -B- of synchro-hub face in same
direction. The recesses for the locking pieces in locking collar and
synchro-hub must be aligned ( ⇒ page 140 ).
– Insert locking pieces (Installation position: ⇒ page 140
– Install spring rings below edge -C- of the locking piece, offset
120°.
Installation positions of spring rings if locking pieces are not hol‐
low:
The curved end of the spring ring must be situated in front of the
locking pieces -arrows-.
Installation positions of spring rings if locking pieces are hollow:
– Curved end of spring ring must engage in hollow interior of
locking piece (⇒ last Fig.).

Installation of spring rings with curved end -A-

These spring rings are installed on both sides.
– Spring are installed only in conjunction with hollow locking
pieces.
– Insert locking pieces (Installation position: ⇒ page 140

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation location of the corrugated
permitted unlessspring washers:
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.
– Insert the washers offset by 120°.
– Angled end of spring washer -A- must locate in hollow locking
piece.
The spring washer must be fitted under the protrusion -B- of lock‐
ing pieces.
Bent ends always face away from synchro-hub
-direction of arrow-.

1.3 Adjusting input shaft

1. Input shaft: 141

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Special tools and workshop

equipment required
♦ Universal dial gauge brack‐
et - VW 387-
♦ Final measurement plate -
VW 385/17-
♦ Pressure disk - VW 510-
♦ Pressure disk - VW 447 i-
♦ Press die - VW 407-
♦ Torque wrench - V.A.G
1331-
♦ Dial gauge - VAS 6080A-

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.

The input shaft must be re-adjusted when the following compo‐

nents are renewed:
♦ Gearbox
♦ clutch housing
♦ Input shaft:
♦ 4th gear wheel
or the
♦ Tapered roller bearing
Adjustment chart ⇒ page 187
Prerequisite:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant .

142 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Press tapered roller bearing outer race into gearbox housing

to stop.

– Press tapered roller bearing outer race without shim into gear‐
box housing to stop.
– Install input shaft in clutch housing and set gearbox housing
in place. Tighten hexagon bolts ⇒ page 95 .

– Install the measuring appliance and dial gauge in clutch hous‐

ing.
– Before measurement, rotate input shaft to allow tapered roller
bearings to settle. Set dial gauge to “0” with 1 mm preload.

Note

This procedure is to be repeated for all further measurements, as

the dial gauge does not otherwise return to the initial position.

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.

1. Input shaft: 143

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Press input shaft in direction of dial gauge

-direction of arrow-.
– Read and note play on dial gauge (example: 1.21 mm).

Note

Dial gauge does not return to original position.

Shim calculation table

Example:
Bearing play, measured value Thickness of shim according to
table
1.21 mm 1.175 mm

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.

144 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Shim table
Bearing clearance Shim
Measured value (mm) Thickness (mm)
0,671 … 0,699 0,650
0,700 … 0,724 0,675
0,725 … 0,749 0,700
0,750 … 0,774 0,725
0,775 … 0,799 0,750
0,800 … 0,824 0,775
0,825 … 0,849 0,800
0,850 … 0,874 0,825
0,875 … 0,899 0,850
0,900 … 0,924 0,875
0,925 … 0,949 0,900
0,950 … 0,974 0,925
0,975 … 0,999 0,950
1,000 … 1,024 0,975
1,025 … 1,049 1,000
1,050 … 1,074 1,025
1,075 … 1,099 1,050
1,100 … 1,124 1,075
1,125 … 1,149 1,100
1,150 … 1,174 1,125
1175 … 1,199 1,150
1,200 … 1,224 1,175
1,225 … 1,249 1,200
1,250 … 1,274, 1,225
1,275 … 1,229 1,250
1,300 … 1,324 1,275
1,325 … 1,349 1,300
1,350 … 1,374 1,325
1,375 … 1,399 1,350
1,400 … 1,424 1,375
1,425 … 1,449 1,400
1,450 … 1,474 1,425
1,475 … 1,499 1,450
1,500 … 1,524 1,475
1,525 … 1,549 1,500
1,550 … 1,574 1,525
1,575 … 1,599 1,550
1,600 … 1,624 1,575
1,625 … 1,649 1,600
1,650 … 1,674 1,625
1,675 … 1,699 1,650
1,700 … 1,724 1,675

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Allocate shims using ⇒ Electronic parts catalogue (ETKA) .
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.

– Remove input shaft and press outer race of tapered roller

bearing out of gearbox housing using thrust plate - VW 447 i- .
– Insert shims of determined thickness, thickest shim first.
If the required thickness for the shim is more than that indicated
on the table, two shims may be fitted together in order to reach
the determined thickness.

1. Input shaft: 145

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Press outer ring of tapered roller bearing together with corre‐

sponding shim (in example 1.175 mm) into gearbox housing
using thrust pad - VW 510- .
– Fit gearbox housing and tighten hexagon bolts.
Check adjustment.

– Install measuring appliance and dial gauge.

– Rotate input shaft to allow tapered roller bearings to settle.
– Press input shaft in -direction of arrow-.
– Bearing clearance should be min. 0.01...max. 0.09 mm.

Note

If the bearing play cannot be measured, but input shaft play is

perceptible and the input shaft turns freely, the adjustment is ac‐
ceptable.

Tightening torques
♦ Gearbox housing to clutch housing ⇒ page 95

1.4 Renewing input shaft seal

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.

Special tools and workshop equipment required

♦ Drift - VW 295-
♦ Adapters - VW 295 A-
♦ Thrust pad - VW 454-
♦ Tube element - 2040-
♦ Sealing grease - G 052 128 A1-
♦ Neither pressure plate - VW 447 H- nor pressure plate - VW
512- are required.
– Remove gearbox.

146 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Remove clutch release lever with release bearing and guide

sleeve ⇒ page 36
Driving oil seal out of guide sleeve

– Half fill the area between the sealing lip and dust lip -arrow-
with sealing grease - G 052 128 A1- .
– Lightly moisten outer circumference of oil seal with gear oil.

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.

Driving oil seal into guide sleeve (drive in onto stop)

– Install clutch release lever together with release bearing and
guide sleeve ⇒ page 36 .
– Install gearbox.
Tightening torques
♦ ⇒ “1.4 Assembly overview - clutch release mechanism”, page
18

1. Input shaft: 147

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

2 Output shaft
⇒ “2.1 Assembly overview - output shaft”, page 148
⇒ “2.2 Input shaft: disassembly and assembly”, page 151
⇒ “2.3 Adjusting output shaft”, page 161

2.1 Assembly overview - output shaft

Note

♦ The output shaft is dismantled as follows: place splitter under 2nd speed selector gear
⇒ Item 21 (page 149) and press off as described in ⇒ page 155 Remove retaining ring
⇒ Item 17 (page 149) . Then press off locking collar with synchro-hub for 1st and 2nd gear as described in
⇒ page 155 .
♦ When installing new gears or new input shaft, refer to ⇒ Electronic parts catalogue (ETKA) and technical
data.
♦ Always renew both tapered roller bearings together as a set.

1 - Hexagonal nut
❑ ⇒ page 98
2 - clutch housing
3 - Shim
❑ From the secondary
shaft.
❑ Adjustment chart
⇒ page 187
4 - Small tapered roller bearing
outer race
❑ Removal ⇒ page 154
❑ Insertion ⇒ page 154
❑ If replaced, adjust the
output shaft
⇒ page 161
❑ Note different versions
when adjusting
⇒ page 164
5 - Tapered roller bearing inner
race small
❑ Pressing out
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
⇒ page 154 respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Insertion ⇒ page 155

6 - Output shaft
❑ setting ⇒ page 161
7 - Tapered roller bearing inner
race large
❑ Pressing out
⇒ page 155
❑ Insertion ⇒ page 156
8 - Oil seal
❑ Place seals (4x) on bolts for bearing mounting

148 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

9 - Bearing support
❑ With large tapered roller bearing outer race and bolts
❑ Only renew outer race together with large tapered roller bearing and bearing mounting
10 - Thrust washer
❑ Shoulder of thrust washer faces tapered roller bearing
11 - Synchromeshed gear for 1st gear
12 - Needle roller bearing
❑ Of 1st gear
13 - Synchro-ring
❑ (Inner ring for 1st gear)
❑ Installation position ⇒ page 156
❑ Check for wear ⇒ page 156
❑ Check that the tabs show no signs of wear
14 - Outer ring for 1st gear
❑ Installation position ⇒ page 156
❑ Check for wear ⇒ page 156
❑ Replace if there are signs of scoring and wear
15 - 1st gear synchro-ring
❑ Installation position ⇒ page 156
❑ Check for wear ⇒ page 156
16 - Locking collar with synchro hub for 1st and 2nd gears
❑ Pull off together with bearing support ⇒ page 155 after removing retaining ring ⇒ Item 17 (page 149)
❑ Dismantling ⇒ page 157
❑ Assembling locking collar and synchro-hub ⇒ page 157 , ⇒ page 157 and ⇒ page 157
❑ Installation position ⇒ page 158
❑ Insertion ⇒ page 158
17 - Securing ring
18 - 2nd gear synchro-ring
❑ Check for wear ⇒ page 156
❑ Insert so that recesses engage in locking pieces of locking collar for 1st and 2nd gear
19 - Outer ring of 2nd gear
❑ place in the synchro-ring of 2nd gear ⇒ Item 18 (page 149)
❑ Installation position ⇒ page 158
❑ Replace if there are signs of scoring and wear
20 - Synchro-ring
❑ (Inner ring for 2nd gear)
❑ Check for wear ⇒ page 156 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
❑ Check that the tabs show no signs of wear
respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Installation position ⇒ page 158

21 - Synchromeshed gear for 2nd gear
❑ Installation position ⇒ page 159
22 - Needle roller bearing
❑ Of 2nd gear
23 - Thrust washer
24 - Sleeve for 3rd gear needle bearing
❑ Pressing off with synchromeshed gear for 2nd gear ⇒ page 155

2. Output shaft 149

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

❑ Insertion ⇒ page 159

25 - Needle roller bearing
❑ for 3rd gear
26 - 3rd speed selector gear
27 - Synchromesh ring of 3rd gear
❑ Check for wear ⇒ page 159
28 - Locking collar with synchro-hub for 3rd and 4th gears
❑ Pressing off with 2nd speed selector gear and 3rd speed selector gear ⇒ page 155
❑ Dismantling ⇒ page 159
❑ Assembling locking collar and synchro-hub ⇒ page 159 , ⇒ page 160 and ⇒ page 160
❑ Installation position of the mobile element/synchromesh body. ⇒ page 160
❑ Insertion ⇒ page 160
29 - Drift sleeve
❑ For needle bearing
❑ Press off with locking collar and synchro-hub for 3rd and 4th gears ⇒ page 155
❑ Insertion ⇒ page 161
30 - Needle roller bearing
❑ For 4th gear
31 - Syncro-ring for 4th gear
❑ Check for wear ⇒ page 159
32 - 4th speed selector gear
33 - Thrust washer
34 - Roller bearing
❑ From the secondary shaft.
❑ Roller bearing without retaining ring and roller bearing with retaining ring
❑ Identifying roller bearing for output shaft in gearbox housing ⇒ page 127
❑ Removing and installing roller bearing without circlip ⇒ page 128 .
❑ Removing and installing roller bearing with circlip ⇒ page 129 .
35 - Gearbox
❑ Modified output shaft roller bearing
❑ Determine according to ⇒ Electronic parts catalogue (ETKA) .
36 - Drift sleeve
❑ For output shaft needle bearing
❑ Pressing out ⇒ page 155
❑ Insertion ⇒ page 161
37 - 5th gear pinion
❑ removing and installing ⇒ page 105
38 - Dished washer
❑ Installation position ⇒ page 123
39 - Plug
❑ Tightening torque ⇒ page 94
❑ Renew after removing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Fitted section of bolt head holds dished
permittedspring in position
unless authorised by SEAT⇒S.A.page
SEAT123
S.A does not guarantee or accept any liability with

❑ removing and installing ⇒ page 105

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

150 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

2.2 Input shaft: disassembly and assembly

Special tools and workshop

equipment required
♦ Press die - VW 407-
♦ Press die - VW 412-
♦ Pressure disk - VW 512-
♦ Puller - V.A.G 1582-
♦ Locking device -
V.A.G 1582/4-
♦ Locking device -
V.A.G 1582/5-

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. Output shaft 151

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Pressure plate - VW 402-

♦ Thrust piece - 32 - 111-
♦ Press die - VW 408 A-
♦ Press die - VW 409-
♦ Mounting rails - VW 457-
♦ Tube element - VW 519-

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.

152 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Thrust ring - VW 429-

♦ Tube element - VW 415 A-
♦ Pressure disk - VW 447 H-
♦ Thrust pad - VW 454-
♦ Assembly sleeve - VW 455-
♦ Drift sleeve - 41-501-

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. Output shaft 153

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Internal puller - 1-
Kukko 21/6-

♦ Counter-support - 4-
Kukko 22/2-
♦ Separator - 3-Kukko
17/2-
Pulling out small tapered
roller bearing outer race
A - Internal puller 37...46
mm , e.g. -Kukko 21/6-
B - Support bracket , ex.
-Kukko 22/2-

Pressing in small tapered roller bearing outer race

Pulling off small tapered roller bearing inner race

A - Vice with protective jaw covers 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
– Fit adapter and tighten behind bearing rollers, then turn bear‐
respect to the correctness of information in this document. Copyright by SEAT S.A.

ing and retighten gripping device.

154 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Pressing on small tapered roller bearing inner race

Pressing off 3rd and 4th gear synchro-hub and locking collar, 2nd,
3rd and 4th gear synchromeshed gears with sleeve for gearbox
housing needle bearing
A - Splitter 22...115 mm , e.g. -Kukko 17/2-
B - Hexagon bolt M10 x 20, 17 mm AF

Note

Support splitter so that the 1st and 2nd gear locking collar is not
pulled off at the same time.

Pressing off locking collar with synchro-hub and bearing support

– First remove retaining ring -arrow-.

Pulling off large tapered roller bearing inner race

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
A - Protective jaws 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.
– Before fitting puller, insert a M 10 x 20 hexagon bolt in the
output shaft drilling.

2. Output shaft 155

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Pressing on large tapered roller bearing inner race

-A- Thrust washer
– Fit thrust washer before pressing on inner race. Shoulder
faces towards inner race.

Installation position of outer ring, inner ring and synchro-ring for

1st gear
– Fit the interior ring -A- onto the mobile pinion for 1st gear.
Angled lugs -arrow 1- face outer ring -B-.
– Fit the outer ring -B-.
The tabs -arrows 2- insert into the recesses -arrows 3- of the mo‐
bile pinion.
– Fit the synchroniser ring -C-.
The recesses -arrow 4- locate on the tabs -arrow 1- of the inner
ring -A-.

Note

If components are not renewed, ensure that they are matched

with their original gears.

Checking 1st and 2nd gear inner ring for wear

– Press inner ring onto cone of synchromeshed gear and meas‐
ure gap -a- using a feeler gauge.
Gap -a- Assembly level Wear limit
1. and 2nd gear 0.75 ... 1.25 mm 0.3 mm

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.

Checking 1st and 2nd gear synchro-ring for wear

– Press synchro ring, outer ring and inner ring against tapered
seat on selector gear and measure gap -a- using a feeler
gauge.
Gap -a- Assembly level Wear limit
1. and 2nd gear 1.2 ... 1.8 mm 0.5 mm

156 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Disassembly and assembly of the mobile element / synchroniser

body unit for 1st and 2nd gear
1 - Spring
Allocate spring rings using ⇒ Electronic parts catalogue (ETKA) .
Installation with hollow locking pieces ⇒ page 157 .
Installation with solid locking pieces ⇒ page 157 .
2 - Mobile element
3 - Synchromesh
4 - Locking elements
Determine locking pieces using ⇒ Electronic parts catalogue .
Collar is equally wide on both sides of synchro-hub.
Collar has chamfer on one side -arrow B-.
Chamfer on collar of synchro-hub and outer teeth of locking collar
-arrow A- face in same direction after assembly.
Notches -arrow C- in synchro-hub and sliding collar for locking
pieces must align.

Assembly of 1st and 2nd gear locking collar and synchro-hub with
hollow locking pieces
• The mobile element is on the synchromesh body.
– Insert the locking elements and install flexible rings offset by
120º. Curved end of spring ring must engage in hollow interior
of locking piece.

Assembly of 1st and 2nd gear locking collar and synchro-hub with
solid locking pieces
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.
• The mobile element is on the synchromesh body.
– Insert the locking elements and install flexible rings offset by
120º.
• The curved end of the spring rings must be situated in front of
the locking pieces -arrows-.

2. Output shaft 157

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Installation position of locking collar with synchro-hub for 1st and

2nd gears
Teeth of locking collar -arrow- face splines for 3rd and 4th gear
synchro-hub -A-.

Pressing on locking collar and synchro-hub for 1st and 2nd gears
Turn the synchromesh ring so that the notches coincide with the
locking elements.

Installation position of 2nd gear outer ring

The lugs -arrows- face towards 1st gear -A-.

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.

Installation position of synchro-ring (2nd gear inner ring) -A-

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

158 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Installation of 2nd gear mesh

The higher shoulder -A- faces towards 1st gear -B-. The collar
grooves -arrows- engage into the outer ring tabs ⇒ page 158 .

Pressing on sleeve for 3rd gear needle bearing

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

– Press synchro-ring onto cone of synchromeshed gear and
measure gap -a- using feeler gauge.
Gap -a- Assembly level Wear limit
1st gear 1.0 ... 1.7 mm 0.5 mm
3rd gear 1.0 ... 1.7 mm
4th gear 1.0 ... 1.7 mm

Dismantling and assembling 3rd and 4th gear locking collar and
synchro-hub
1 - Spring
Allocate spring rings using ⇒ Electronic parts catalogue (ETKA) .
Installation with hollow locking pieces ⇒ page 157 .
Installation with solid locking pieces ⇒ page 157 .
2 - Locking elements
Determine locking pieces using ⇒ Electronic parts catalogue .
3 - Mobile element
4 - Synchromesh
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
–permitted
Slide locking
unless collar
authorised over
by SEAT synchronising
S.A. SEAT hub. or accept any liability with
S.A does not guarantee
respect to the correctness of information in this document. Copyright by SEAT S.A.
The recesses of the synchromesh assembly and mobile element
must lie over another for the locking elements.

2. Output shaft 159

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Assembly of 3rd and 4th gear locking collar and synchro-hub with
hollow locking pieces
The mobile element is on the synchromesh body.
– Insert the locking elements and install flexible rings offset by
120º. Curved end of spring ring must engage in hollow interior
of locking piece.

Assembly of 3rd and 4th gear locking collar and synchro-hub with
solid locking pieces
• The mobile element is on the synchromesh body.
– Insert the locking elements and install flexible rings offset by
120º. The curved end of the spring rings must be situated in
front of the locking pieces -arrows-.
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.

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

4th gears
Chamfer -arrow- faces 4th gear.

Pressing on synchro-hub with locking collar for 3rd and 4th gears

160 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Pressing on sleeve for 4th gear needle bearing

Pressing on sleeve for needle bearing/output shaft

2.3 Adjusting output shaft

(Determining thickness of output shaft shim)

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. Output shaft 161

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Special tools and workshop

equipment required
♦ Universal dial gauge brack‐
et - VW 387-
♦ Final measurement plate -
VW 385/17-
♦ Pressure disk - VW 512-
♦ Straightening tool - 3114/2-
♦ Press die - VW 407-
♦ Torque wrench -
V.A.G 1331-
♦ Dial gauge - VAS 6080A-

♦ Internal puller - 1-Kukko 21/6-

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.

♦ Counter-support - 4-Kukko 22/2-

The output shaft must be re-adjusted when the following compo‐
nents are renewed:
♦ Output shaft
♦ clutch housing
or
♦ Tapered roller bearing

162 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Adjustment chart ⇒ page 187

Requirements:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant .
– Press outer ring of small tapered roller bearing to stop without
shim into clutch housing ⇒ page 154 .
– Insert output shaft and tighten nuts for bearing mounting.
– Turn output shaft 20 to 30 times in one direction.

Note

♦ The shaft must be turned in one direction so that the rollers of

the tapered roller bearing settle in one direction.
♦ It is necessary to turn the shaft 20 to 30 times to achieve this.
♦ Otherwise the resulting reading will be incorrect.

– Mount dial gauge (3 mm measuring range) and set to “0” with

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

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. Output shaft 163

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Identifying tapered roller bearings

The following tapered roller bearings might be installed:
♦ I = Outer races for tapered roller bearing “without shoulder”
♦ I = Outer races for tapered roller bearing “with shoulder”
-arrow-
Shim table
Outer race for tapered roller bearing “without shoulder” = item I
⇒ page 164
Measured value Shim
thickness (mm)
... 0,579 0,600
0,580 … 0,629 0,650
0,630 … 0,679 0,700
0,680 … 0,729 0,750
0,730 … 0,779 0,800
0,780 … 0,829 0,850
0,830 … 0,879 0,900
0,880 … 0,929 0,950
0,930 … 0,979 1,000
0,980 … 1,029 1,050
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
1,030 … 1,079 1,100
respect to the correctness of information in this document. Copyright by SEAT S.A.
1,080 … 1,129 1,150
1,130 … 1,179 1,200
1,180 … 1,229 1,250
1,230 … 1,279 1,300
1,280 … 1,329 1,350
1,330 … 1.342 1,400
Shim table
Outer race for tapered roller bearing “with shoulder” = item II
⇒ page 164
Bearing play = Shim
(0.65 mm shim thickness (mm)
plus determined measured val‐
ue)
... 0,629 0,650
0,630 … 0,679 0,700
0,680 … 0,729 0,750
0,730 … 0,779 0,800
0,780 … 0,829 0,850
0,830 … 0,879 0,900
0,880 … 0,929 0,950
0,930 … 0,979 1,000
0,980 … 1,029 1,050
1,030 … 1,079 1,100
1,080 … 1,129 1,150
1,130 … 1,179 1,200
1,180 … 1,229 1,250
1,230 … 1,279 1,300
1,280 … 1,329 1,350
1,330 … 1,379 1,400
1,380 … 1.429 1,450

Note

Allocate shims using ⇒ Electronic parts catalogue (ETKA) .

164 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Remove output shaft and pull out small tapered roller bearing
outer race ⇒ page 154
– Insert shims of determined thickness, thickest shim first.
If the required thickness for the shim is more than that indicated
on the table, two shims may be fitted together in order to reach
the determined thickness.
The existence of different thickness shims will enable the selec‐
tion of the correct thickness required.
– Press in outer race of small tapered roller bearing together with
the calculated shim ⇒ page 154 and install output shaft.
– Tighten nut for bearing mounting in clutch housing.
Tightening torques
♦ Bearing mounting to clutch housing ⇒ page 98

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. Output shaft 165

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

3 Reverse gear shaft:

⇒ “3.1 Assembly overview - reverse shaft”, page 166
⇒ “3.2 Dismantling and assembling reverse shaft”, page 167

3.1 Assembly overview - reverse shaft

Note

After removal, renew needle bearings in clutch housing and in reverse shaft support.

1 - clutch housing
2 - Needle bearing shell
❑ Remove ⇒ page 168
❑ Insertion ⇒ page 168
3 - Reverse gear pinion
4 - Securing ring
❑ Replace after each re‐
moval
5 - Reverse gear synchro‐
meshed gear 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 locking ring has to respect to the correctness of information in this document. Copyright by SEAT S.A.
be removed before in‐
stalling
❑ Shoulder faces reverse
gear wheel
6 - Reverse gear shaft:
❑ removing and installing
⇒ page 111
7 - Needle bearing shell
❑ Pressing out
⇒ page 168
❑ Insertion ⇒ page 169
8 - Reverse shaft support
❑ removing and installing
⇒ page 111

166 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

3.2 Dismantling and assembling reverse shaft

Special tools and workshop

equipment required
♦ Thrust pad - VW 454-
♦ Pressure disk - VW 447 H-
♦ Press die - VW 411-
♦ Centring mandrel. - 12 -
551-
♦ Pressure plate - VW 401-
♦ Press die - VW 408 A-

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.

3. Reverse gear shaft: 167

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ -1- Interior extractor -

Kukko 21/2-

♦ -4- Counterhold tool -

Kukko 22/1-
Pulling needle bearing
out of clutch housing
A - Support bracket , ex.
-Kukko 22/1-
B - Internal puller
14.5...18.5 mm , e.g. -
Kukko 21/2-

Note

The needle bearing is

destroyed during remov‐
al and must be renewed.

Pressing needle bearing -A- into clutch housing

Pressing needle bearing out of reverse shaft support

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.

168 Rep. gr.35 - Gears, shafts

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Pressing needle bearing into reverse shaft support

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.

3. Reverse gear shaft: 169

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

39 – Final drive - front differential

1 Oil seals
⇒ “1.1 Location overview - seals”, page 170
⇒ “1.2 Renewing left oil seal”, page 171
⇒ “1.3 Renewing right oil seal”, page 173

1.1 Location overview - seals

1 - Oil seal
❑ For the input shaft
❑ renew ⇒ page 146
2 - Oil seal
❑ For right-hand articula‐
tion flange
❑ renew ⇒ page 173
3 - Oil seal
❑ For left flange shaft
❑ renew ⇒ page 171
4 - Oil seal
❑ For selector shaft
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ renew ⇒ page 101 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.

170 Rep. gr.39 - Final drive - front differential

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

1.2 Renewing left oil seal

⇒ “1.2.1 Renewing oil seal for left flange shaft”, page 171

1.2.1 Renewing oil seal for left flange shaft

Special tools and workshop

equipment required
♦ Universal tool - VW 771-
♦ Puller hooks - VW 771/37-
♦ Thrust pad - T10160-
♦ Tray - V.A.G 1306-
♦ or drip tray for workshop
hoist - VAS 6208- permitted
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ Torque wrench - respect to the correctness of information in this document. Copyright by SEAT S.A.

V.A.G 1331-

Removal:
– Remove wheel.
– Remove the noise insulation ⇒ Bodywork, exterior fitting work;
Rep. gr. 66 .
– Turn steering to the left.
– Remove the front left-hand wheel housing shell ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing shell; front
wheel housing shell - assembly overview .

1. Oil seals 171

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Remove coupling rod -1- from the stabiliser ⇒ Running gear,

axles, steering; Rep. gr. 40 ; Repair front wheel suspension;
Front axle - assembly overview .
– Unscrew drive shaft from the flange shaft ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Repair front wheel suspension;
Front axle - assembly overview .
– Raise drive shaft as high as possible and secure. Take care
not to damage paint on drive shaft in the process.
– Place below the collecting tray .

– Extract the bolt fastening the flanged shaft. To do so, thread

two bolts on the flange and lock the shaft using the assembly
lever.
– Remove flanged shaft together with compression spring.

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.

– Remove the flanged shaft seal with the universal tool - VW

771- and the extractor hook - VW 771/37- .

Installation
– Lightly oil outer circumference of new oil seal.
– Fit a new seal as far as possible without tilting.

172 Rep. gr.39 - Final drive - front differential

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Half fill the area between the sealing lip and dust lip -arrow-
with sealing grease - G 052 128 A1- .
– Insert flange shaft.
– Press flange shaft against gearbox and secure.
– Connect drive shafts to the gearbox ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Repair front wheel suspension; Front
axle - assembly overview .

– Install coupling rod -1- from the stabiliser ⇒ Running gear,

axles, steering; Rep. gr. 40 ; Repair front wheel suspension;
Front axle - assembly overview .
– Check and top up gear oil ⇒ page 87 .
– Install the left wheel housing shell ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing shell; front wheel hous‐
ing shell - assembly overview .
– Install noise insulation ⇒ General body repairs exterior; Rep.
gr. 66 .
– Install wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torques for wheel bolts .
Tightening torque
♦ Flange shaft to gearbox ⇒ page 177

1.3 Renewing right oil seal

⇒ “1.3.1 Renewing oil seal for right flange shaft”, page 173

1.3.1 Renewing oil seal for right flange shaft

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.

1. Oil seals 173

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

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

Special tools and workshop equipment required

♦ Thrust pad - T10148-
♦ Spindle from assembly tool - 3066-
♦ Universal tool - VW 771-
♦ Puller hooks - VW 771/37-
♦ Torque wrench - V.A.G 1331-
♦ Tray - V.A.G 1306-
♦ or drip tray for workshop hoist - VAS 6208-

174 Rep. gr.39 - Final drive - front differential

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Removal:
The drive shaft must be removed in a later step.
– With the vehicle still standing on all four wheels, loosen the
front flange bolt by a maximum of 90° -arrow- so as not to
damage the wheel bearing ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Repair front wheel suspension; Front axle - as‐
sembly overview .
– Remove the noise insulation ⇒ Bodywork, exterior fitting work;
Rep. gr. 66 .
– Turn steering to full right lock.

– If fitted, remove drive shaft heat shield -arrows- ⇒ Running

gear, axles, steering; Rep. gr. 40 ; Repair front wheel sus‐
pension; Front axle - assembly overview .
– Remove drift shaft⇒ Running gear, axles, steering; Rep. gr.
40 ; Repair front wheel suspension; Front axle - assembly
overview .
– Place below the collecting tray .

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.
– Extract the bolt fastening the flanged shaft. To do so, thread
two bolts on the flange and lock the shaft using the assembly
lever.
– Remove flanged shaft together with compression spring.

The seal is located in a metal sleeve.

– Pull out seal and sleeve together.
A projection is located on inside diameter of sleeve.
– Apply puller hooks - VW 771/37- directly behind shoulder in
sleeve
– When extracting, the puller hook - VW 771/37- must be press‐
ed tightly into the sleeve.

1. Oil seals 175

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Installation
– Clean seat for seal in gearbox.
– Pull in seal and sleeve together.
A - Screw spindle of assembly tool - 3066- into threaded piece of
differential.
B - Nut M12
– Turn nut -B- and pull oil seal with sleeve in onto stop with thrust
piece - T10148- .

– Half fill the area between the sealing lip and dust lip -arrow-
with sealing grease - G 052 128 A1- .
– Insert flange shaft.
– Press flange shaft against gearbox and secure.
– Install drift shaft⇒ Running gear, axles, steering; Rep. gr. 40 ;
Repair front wheel suspension; Front axle - assembly over‐
view .

– If fitted, install drive shaft heat shield -arrows- ⇒ Running gear,

axles, steering; Rep. gr. 40 ; Repair front wheel suspension;
Front axle - assembly overview .
– Check and top up gear oil ⇒ page 87 .
– Install noise insulation ⇒ General body repairs exterior; Rep.
gr. 66 .
Tightening torque
♦ Flange shaft to gearbox ⇒ page 177

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.

176 Rep. gr.39 - Final drive - front differential

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

2 Differential:
⇒ “2.1 Assembly overview - differential”, page 177
⇒ “2.2 Differential: assembly and disassembly”, page 178
⇒ “2.3 Adjusting differential”, page 184

2.1 Assembly overview - differential

1 - Gearbox
2 - Shim
❑ For the differential
❑ Determine thickness
⇒ page 184
3 - Outer track, roller bearing
❑ Remove ⇒ page 181
❑ Insertion ⇒ page 181
4 - Inner ring and roller bearing
unit
❑ Pressing out
⇒ page 181
❑ Insertion ⇒ page 181
5 - Differential:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ With differential crown 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 - Inner ring and roller bearing
unit
❑ Pressing out
⇒ page 181
❑ Insertion ⇒ page 181
7 - Outer track, roller bearing
❑ Pressing out
⇒ page 180
❑ Insertion ⇒ page 180
8 - clutch housing
9 - Oil seal
❑ With sleeve
❑ For right-hand articula‐
tion flange
❑ If seal is damaged, re‐
new seal and sleeve together ⇒ page 173
10 - Countersunk bolt
❑ 25 Nm
11 - Flange shaft
❑ removing and installing ⇒ page 170
12 - Flanged shaft compression spring
13 - Thrust washer
❑ Installation position ⇒ page 183
14 - Tapered ring
❑ With slots for the thrust washer
❑ Installation position: conical side facing the differential casing

2. Differential: 177
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

15 - Securing ring
❑ Keep the following in position: conical ring, shim and pressure spring for flanged shaft when it is dis‐
mantled
16 - Oil seal
❑ For left flange shaft
❑ renew ⇒ page 171

2.2 Differential: assembly and disassembly

Special tools and workshop

equipment required
♦ Roller bearing bush extrac‐
tor - V.A.G 1582-
♦ Locking device - V.A.G
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1582/3- 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.

♦ Press die - VW 412-

♦ Pressure plate - VW 401-
♦ Pressure plate - VW 402-

178 Rep. gr.39 - Final drive - front differential

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Press die - VW 408 A-

♦ Thrust pad - VW 473-
♦ Pressure plate - 30 - 205-
♦ Drift sleeve - 3144-
♦ Thrust pad - 2007-
♦ Torque wrench - V.A.G
1332-

♦ Inlay socket - 40 - 21-

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. Differential: 179
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

♦ Pressure plate - 40-105-

♦ Internal puller - 1-Kukko 21/7-

♦ Counter-support - 4-Kukko 22/2-

Note

♦ Heat tapered roller bearing inner race to 100° C before instal‐

ling.
♦ Always renew both tapered roller bearings together as a set.
♦ If tapered roller bearings, differential cage, gearbox housing
or clutch housing is renewed, adjust differential ⇒ page 187 .

Remove the outer ring of the conical roller bearing from the clutch
housing 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
– First remove seating sleeve for flange shaft seal.
respect to the correctness of information in this document. Copyright by SEAT S.A.

Pressing tapered roller bearing outer race into clutch housing

No shim is installed in the clutch housing end.

180 Rep. gr.39 - Final drive - front differential

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Pulling off tapered roller bearing inner races

– Before installation of puller, position thrust plate - 40 - 105- on
differential cage.

Note

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

Fit inner ring and roller bearing units

Note

The inner races of tapered roller bearings for gearbox housing

and clutch housing are pressed on with the same press tools.

Remove the outer ring of the roller bearing from the gearbox cas‐
ing
A - Support bracket , ex. -Kukko 22/2-
B - Internal puller 46...58 mm , e.g. -Kukko 21/7-

Pressing tapered roller bearing outer race into gearbox housing

– Fit shim under outer race.
– Support gearbox housing directly below bearing mounting us‐
ing sleeve - 3144- .

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. Differential: 181
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Spring pin identification

Value “a” mm Distinguishing feature
28.5 (short spring pin), Circumferential groove
removing and installing ⇒ page 182 -arrows-
36.0 (long spring pin), No circumferential
Removing ⇒ page 182 , groove
Installing ⇒ page 183

Allocation of differential cages

The hole in the differential cage was modified for the longer spring
pin. 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.
Bore Length of spring pin (mm)
-A- 28.5 (short spring pin)
-A- and -B- 36.0 (long spring pin)

Removing and installing spring pin with circumferential groove

(short spring pin)
Removal:
– Cover tapered roller bearing inner race and speedometer drive
gear to avoid possible damage and ingress of metal particles.
– Drive out spring pin with chisel, inserting chisel into circum‐
ferential groove.
Installation
– Fit to the differential casing as far as it will go.

Removing spring pin without circumferential groove (long spring

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

182 Rep. gr.39 - Final drive - front differential

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Installing spring pin without circumferential groove (long spring

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

On some versions the one-piece thrust washer has a projection

next to the holes -A-.
In this case, the differential cage has a circumferential groove
-B-.
– Lubricate one-piece thrust washer with gear oil and install.
– Install one-piece thrust washer so that it engages in groove
-B- in differential cage.
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.

Installing differential bevel gears and differential pinion pin

– Lubricate one-piece thrust washer with gear oil and install.
– Install both sun wheels and secure (e.g. with flange shaft).
– Fit the small planetary gears offset by 180° and rotate them
inwards.
– Press in differential pinion pin (-arrow A-) to first planet pinion.
– Place threaded pieces -arrows B- in sun gears.
Installation position: rebate faces differential box gear train.
– Drive differential pinion pin into final position and secure with
spring pin.

Installation position of thrust washer for tapered ring -1-.

Collar -arrow- faces spring -B-.
Some gearboxes have lugs -A-.
Lugs -A- face tapered ring -1-.

2. Differential: 183
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

2.3 Adjusting differential

Special tools and workshop

equipment required
♦ Universal dial gauge brack‐
et - VW 387-
♦ Final measurement plate -
VW 385/17-
♦ Press die - VW 407-
♦ Pressure plate - 30 - 205-
♦ Torque wrench -
V.A.G 1331-
♦ Internal puller - 1 - Kukko
21/7-
♦ Counter-support - 4 - Kukko
22/2-
♦ Dial gauge - VAS 6080A-

The differential must always be adjusted when any one of the

following elements have been changed:
♦ Gearbox
♦ clutch housing
♦ Differential casing
or the
♦ Differential conical roller bearings
Adjustment chart ⇒ page 187 .
– Press outer race of tapered roller bearing without shim into
205- ⇒unless
gearbox housing using thrust piece - 30 - permitted page 181 by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
authorised
respect to the correctness of information in this document. Copyright by SEAT S.A.

Note

The inner and outer roller bearing rings are paired. Do not mix
them up.

184 Rep. gr.39 - Final drive - front differential

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

– Press outer race of tapered roller bearing into clutch housing

using thrust plate - 30 - 205- ⇒ page 180 .
– Place the differential on the clutch housing.
– Set gearbox housing in place and tighten 5 bolts to 25Nm.
– Attach dial gauge and set to “0” with 1 mm preload.
– Move differential up and down. Read and note play indicated
on dial gauge. (Example: 0.70 mm.)
Shim calculation table
Example:
Bearing play, measured value Thickness of shim according to
table
0.70 mm 0.95 mm
Shim table
Bearing clearance Shim
Measured value Thickness
(mm) (mm)
0,303 … 0,449 0,650
0,450 … 0,499 0,700
0,500 … 0,549 0,750
0,550 … 0,599 0,800
0,600 … 0,649 0,850
0,650 … 0,699 0,900
0,700 … 0,749 0,950
0,750 … 0,799 1,000
0,800 … 0,849 1,050
0,850 … 0,899 1,100
0,900 … 0,949 1,150
0,950 … 0,999 1,200
1,000 … 1,049 1,250
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
1,050 … 1,099 1,300to the correctness of information in this document. Copyright by SEAT S.A.
respect
1,100 … 1,149 1,350
1,150 … 1,199 1,400

Note

Allocate shims using ⇒ Electronic parts catalogue (ETKA) .

– Remove the gearbox casing and pull the outer ring / conical
roller bearing out of the gearbox housing.

2. Differential: 185
 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

Remove the outer ring of the roller bearing from the gearbox cas‐
ing
A - Support bracket , ex. -Kukko 22/2-
B - Internal remover 46... 58 mm , e.g. -Kukko 21/7-
– Insert shims of determined thickness, thickest shim first.
If the required thickness for the shim is more than that indicated
on the table, two shims may be fitted together in order to reach
the determined thickness.
The existence of different thickness shims will enable the selec‐
tion of the correct thickness required.
– Press in outer race of tapered roller bearing again
⇒ page 181 and bolt gearbox housing tight.
Tightening torques
♦ Gearbox housing to clutch housing ⇒ page 95

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.

186 Rep. gr.39 - Final drive - front differential

 Toledo 2013 ➤
5-speed manual gearbox 0A4 - Edition 05.2016

3 Adjustment chart

Note

It is necessary to adjust input shaft, output shaft, or differential

only if components have been renewed which have a direct effect
on the adjustment of the gearbox. To prevent unnecessary ad‐
justments, refer to the following table:

Components requiring adjustment:

Input shaft Output shaft Differential
⇒ page 141 ⇒ page 161 ⇒ page 184
Components renewed: Gearbox x x
clutch housing x x x
Input shaft: x
Output shaft x
Differential casing x
Conical roller bearing for input shaft x
Conical roller bearing of the output x
shaft
Differential roller bearings x
4th gear wheel x

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.

3. Adjustment chart 187