D3E804F5187-6-Speed Manual Gearbox 02U

Service
Workshop Manual
Toledo 2013 ➤
6-speed manual gearbox 02U
Edition 11.2015
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2015 Seat S.A D3E804F5187

Toledo 2013 ➤
6-speed manual gearbox 02U - Edition 11.2015
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when using testers and measuring instruments during a road test . . . . 1
2 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Filling quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
5.1 respect General notesof information
to the correctness . . . . . .in. this
. . document.
. . . . . . Copyright
. . . . . .by. SEAT
. . . S.A.
................................... 7
5.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3 Gaskets, seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.4 Bolts, nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.1 Fitting location overview - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Clutch mechanism: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Overview - clutch actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4 Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.5 Clutch hydraulics (vehicles from MY16) - assembly overview . . . . . . . . . . . . . . . . . . . . . . 21
1.6 Clutch pedal switch F36 : Removal / installation and adjustment . . . . . . . . . . . . . . . . . . . . 24
1.7 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.8 Removing and installing clutch pedal with spring, left-hand drive vehicle . . . . . . . . . . . . . . 30
1.9 Removing and installing clutch pedal, left-hand drive vehicle . . . . . . . . . . . . . . . . . . . . . . 33
1.10 Removing and installing clutch pedal (vehicles from MY16) . . . . . . . . . . . . . . . . . . . . . . . . 35
1.11 Installing and removing bearing bush (vehicles from MY16) . . . . . . . . . . . . . . . . . . . . . . . . 37
1.12 Installing and removing over-centre spring (vehicles from MY16) . . . . . . . . . . . . . . . . . . . . 38
1.13 Removing and installing clutch mechanism lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.14 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.15 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.16 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.17 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2 Clutch release assembly - Installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3 Clutch: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1 Gear mechanism: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.1 Installation position - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.2 Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.3 Assembly overview - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.4 Removing and fitting the gear lever knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.5 Gear lever and protective housing: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.6 Gear selection mechanism cables: removing and fitting; general overview . . . . . . . . . . . . 60
1.7 Gearbox mechanism: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.8 Gear drive mechanism: adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2 Gearbox : removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Contents i
Toledo 2013 ➤
2.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

2.3 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3 Checking gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4 Gearbox: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.1 General layout of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.3 Cover for gearbox casing and 5th/6th gear: removing and installing – general overview . . 86
4.4 Assembly overview - removing and installing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . 88
4.5 Removing and installing input shaft, output shaft, differential, selector mechanism and
selector forks - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.6 Dismantling and assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5 Gearbox casing and clutch housing: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6 Gearbox casing cover: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7 Gear mechanism: repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
8 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

1 Input shaft: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.1 Input shaft: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.2 Disassembly and assembly of thepermitted inputunless
shaftauthorised
. . . .by. SEAT
. . . S.A.
. . .SEAT
. . .S.A
. .does
. . not
. . guarantee
. . . . . or
. .accept
. . . any
. . liability
. . 125
with
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.1 Output shaft: Installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

2.2 Input shaft: disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

1 Replace seals for flanged shafts with installed equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.2 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2.1 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2.2 Differential: assembly and disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.3 Differential: Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
ii Contents
Toledo 2013 ➤
00 – Technical data
1 Safety instructions
(20; Edition 11.2015)
⇒ “1.1 Safety precautions when working on vehicles with a start/
stop system”, page 1
⇒ “1.2 Safety precautions when using testers and measuring in‐
struments during a road test”, page 1
1.1 Safety precautions when working on ve‐

hicles with a start/stop system
WARNING
On vehicles with start-stop system, there is the risk of injury

from automatic engine start.
♦ When working on a vehicle, always deactivate the start/
stop system. Switch ignition OFF.
♦ If required switch on the ignition for a short period of time.
1.2 Safety precautions when using testers

and measuring instruments during a
road test
If test and measuring devices are required during test drives, ob‐
serve the following information:
WARNING
There is a risk of accident from unintended motion and insuf‐

ficient securing of testers and measuring instruments.
There is a risk of injury from the release of the passenger air‐
bag in the event of an accident.
• Operation of test and measuring instruments by the driver
while driving may result in deviating from the direction of
travel.
• There is an increased risk of injury or accident from un‐
secured testers and measuring instruments.
♦ Fasten test and measurement equipment with a strap on
the rear seat and secure their operation by another person
sitting on the rear seat.
1. Safety instructions 1
Toledo 2013 ➤
2 Gearbox identification
The 6-speed manual gearbox 02U is installed in the Toledo 2013
►.
Location on gearbox
Code letters and date of manufacture -arrow 1-, manual
gearbox 02U -arrow 2-.
Gearbox type
6-speed manual gearbox 02Q -arrows 2-
Engine code and manufacture date of gearbox

Example: MFV 25 11 9
I I I I
I I I I
Engine codes Day Month Year (2009)
of manufacture
Additional data identify the factory where the unit was built
Note
The gearbox identification letters are also written on the technical

data sheet of the vehicle.
2 Rep. gr.00 - Technical data

Toledo 2013 ➤
3 Overview - power transmission

Identification
The -arrows- point forwards.
1 - Engine
2 - Coupling unit
3 - 5-speed manual gearbox
4 - Input shaft:
5 - Output shaft
6 - Differential
Gear ratios
The -arrows- point forwards.
3. Overview - power transmission 3

Toledo 2013 ➤
I - gear
II - 2. gear
III - 3. gear
IV - 4. gear
V - gear
VI - 6. gear
R - Reverse
A - Final group
T - Speedometer drive
Replaced by a plug

Toledo 2013 ➤
4 Technical data
⇒ “4.1 Filling quantity”, page 5
⇒ “4.2 Allocation gearbox - engine”, page 5
⇒ “4.3 Calculation of gear ratios”, page 6
4.1 Filling quantity

Capacity of manual gearbox 2.0 l
4.2 Allocation gearbox - engine

Manual gearbox 6-speed 02U
Gearbox: Engine codes NBU NTD
Manufacture from 07.2012 07.2012
to 05.2014 05.2015
Allocation Engine 1.2 ltr./77 kW TSI
Oil specification ⇒ Electronic Catalogue of Original Parts
Clutch action hydraulic
Clutch plate ∅ ⇒ Electronic Catalogue of Original Parts
Drive shaft flange ∅ 100 mm

Gearbox: Engine codes PRN PRP
to 05.2015 05.2015

Gearbox: Engine codes PRQ PPA
to
4. Technical data 5
Toledo 2013 ➤
4.3 Calculation of gear ratios

Example:
5. rd gear Final group
Drive 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
itotal. = Total ratio = iG × iA = 0.717 × 2.917 = 2.091
1) Z1 = Number of teeth of driving gear, Z2 = number of teeth of driving gear.

Toledo 2013 ➤
5 Repair notes
⇒ “5.1 General notes”, page 7
⇒ “5.2 Contact corrosion”, page 9
⇒ “5.3 Gaskets, seals”, page 9
⇒ “5.4 Bolts, nuts”, page 10
5.1 General notes

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. 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
Protected used in
by copyright. this workshop
Copying manual,
for private or commercial purposes, in part or in whole, is not
see ⇒ Workshop equipment permittedand
unlessspecial
authorised tools
by SEAT. S.A. SEAT S.A does not guarantee or accept any liability with
Gearbox:
♦ When installing, ensure that the dowel sleeves between the
engine and gearbox are correctly located.
♦ When installing mounting brackets or waxed components,
clean the contact surfaces. The contact surfaces must be free
of wax and grease.
♦ Bolts and other attachments should have a classification in the
⇒ Electronic Catalogue of Original Parts .
♦ Following installation, check gear oil level
⇒ “3 Checking gear oil”, page 82 .
♦ Gearbox oil ⇒ Electronic catalogue of original parts .
♦ Oil capacity ⇒ “4.1 Filling quantity”, page 5
Securing rings
5. Repair notes 7
Toledo 2013 ➤
♦ Do not over-expand safety rings.

♦ Installation location of several retaining rings: the ring is »in
the upper section« as well as in its installation location. This
make it possible for the pliers to gain a better grip during re‐
moval and installation.
♦ Always renew retaining rings which have been damaged or
used.
♦ The retaining rings must locate properly in the grooves.
♦ Renew spring pins. Installation position: The groove-A- must
remain parallel to the direction of the flow of pressure
-arrow-.
Antifriction bearings
♦ Lubricate all bearings with gear oil before installing.
♦ The inner rings of the tapered roller bearing must be heated
to about 100 °C before the installation with the inductive heater
unit - VAS 6414- . Engage to stop without allowing axial clear‐
ance.
♦ Do not interchange the outer and inner ring of a conical roller
bearing with those of another with the same size. The bearings
come in matched pairs.
♦ Tapered roller bearings fitted to one shaft must be replaced as
a set. Use same make of bearings.
♦ Install needle bearings, ball sleeves and roller sleeves with
lettered side (thicker metal) towards fitting tool.
Shims
♦ Measure shims at several points with a micrometer. The var‐
ious 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

Toledo 2013 ➤
♦ Do not interchange. When reusing synchro-rings, always fit to

the same selector gear.
♦ Check for wear and renew if necessary.
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
flat spots (worn grooves).
♦ Make sure that the coating of coated synchro-rings is not dam‐
aged.
♦ If an intermediate ring -B- is installed, check the outer friction
surface -arrow 2- and inner friction surface -arrow 3- of this
intermediate ring for »scoring« and »signs of abnormal wear«.
♦ Check the cone of the synchromeshed gear for »scoring« and
»signs of abnormal wear«.
♦ Lubricate synchro-rings with gear oil before installing.
Gears and synchro-hubs
♦ The synchro-hubs must be heated to about 100 °C before the
installation with the inductive heater unit - VAS 6414- . Engage
to stop without allowing axial clearance.
♦ The gear wheels must be heated to about 100 °C before the
installation with the inductive heater unit - VAS 6414- . Engage
to stop without allowing axial clearance.
♦ Observe installation position.
Synchromeshed gears
♦ After assembly, check synchromeshed gears for slight play, or
for freedom of movement.
Coupling unit
♦ Do not tilt the clutch pressure plate; release and tighten cross‐
wise in small 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.
5.2 Contact corrosion

The gearbox housing and the clutch housing are made out of
magnesium alloy.
Bolts and other components in direct contact with the gearbox
have surfaces matched to it.
The use of substitute components causes contact corrosion
(screws. nuts. washers ...). The gearbox housing and the clutch
housing are damaged.
Generally install parts which are indicated in the ⇒ Electronic
Catalogue of Original Parts .
5.3 Gaskets, 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. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5. Repair notes 9
Toledo 2013 ➤
Before installing radial shaft seals, lightly oil outer diameter and
half-fill space between sealing lips -arrow- with sealing grease -
G 052 128 A1- .
The open side of the oil seal faces the side with fluid filling.
After installing, check oil level and top up
⇒ “3 Checking gear oil”, page 82 .
Before inserting lightly oil the O-rings, in order to prevent the rings
being squashed during installation.
Sealant
♦ Thoroughly clean housing joint surfaces before applying seal‐
ing paste .
♦ Apply sealing paste - AMV 188 200 03- uniformly but not too
thick.
5.4 Bolts, nuts

♦ Loosen and tighten bolts or nuts for fastening covers or hous‐
ings in a criss-cross manner.
♦ Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts in stages in a diag‐
onal sequence.
♦ Specified torques given are for unlubricated nuts, bolts and
screws. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Always renew self-locking nuts and bolts. respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ It is important to ensure at all bolted connections that the con‐

tact surfaces as well as the nuts and bolts are waxed only after
being installed, should this be necessary.
♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
♦ Check pitch of thread, to ensure correct thread chaser is used
to clean threads and to ensure the threads are not damaged.

Toledo 2013 ➤
6 Electrical components
⇒ “6.1 Fitting location overview - electrical components”,
page 11
6.1 Fitting location overview - electrical

components
⇒ “6.1.1 Fitting location overview - electrical components, manual
gearbox”, page 11
⇒ “6.1.2 Fitting location overview - electrical components, clutch
mechanism”, page 11
6.1.1 Fitting location overview - electrical components, manual gearbox
1 - Reversing light switch - F4-

❑ Fitting location: beneath
starter
❑ removing and fitting
⇒ Item 15 (page 89)
2 - Gearbox Protected
neutralbyposition
copyright. Copying for private or commercial purposes, in part or in whole, is not
sender - G701-
❑ Location: In area of se‐
lector unit beneath an‐
gled rod for securing
selector shaft
6.1.2 Fitting location overview - electrical

components, clutch mechanism
Clutch position sender - G476- (-arrow A- and -arrow B-).
Fitting location:
In engine compartment beneath supply hose -1- on clutch cylinder
-2- above line -3-.
Removing clutch position sender - G476- ⇒ page 27 , installing
⇒ page 28 .
6. Electrical components 11
Toledo 2013 ➤
Checking clutch pedal switch - F36-

Location: In passenger compartment, installed from plenum
chamber bulkhead on mounting bracket for clutch pedal
(-arrows-).
Removing and installing clutch pedal switch - F36- ⇒ page 24

Toledo 2013 ➤
30 – Clutch
1 Clutch mechanism: repairs
⇒ “1.1 Overview - clutch actuation”, page 13
⇒ “1.2 Assembly overview - pedal cluster”, page 15
⇒ “1.3 Assembly overview - hydraulics (LHD)”, page 18
⇒ “1.4 Assembly overview - hydraulics (RHD)”, page 20
⇒ “1.5 Clutch hydraulics (vehicles from MY16) - assembly over‐
view”, page 21
⇒ “1.6 Clutch pedal switch F36 : Removal / installation and ad‐
justment”, page 24
⇒ “1.7 Removing and installing mounting bracket”, page 25
⇒ “1.8 Removing and installing clutch pedal with spring, left-hand
drive vehicle”, page 30
⇒ “1.9 Removing and installing clutch pedal, left-hand drive vehi‐
cle”, page 33
⇒ “1.10 Removing and installing clutch pedal (vehicles from
MY16)”, page 35
⇒ “1.11 Installing and removing bearing bush (vehicles from
MY16) ”, page 37
⇒ “1.12 Installing and removing over-centre spring (vehicles from
MY16)”, page 38
⇒ “1.13 Removing and installing clutch mechanism lines”,
page 39
⇒ “1.14 Removing and installing clutch master cylinder”,
page 42
⇒ “1.15 Removing and installing clutch slave cylinder”,
page 44
⇒ “1.16 Removing and installing clutch position sender G476 ”,
page 44
⇒ “1.17 Bleeding clutch system”, page 46
1.1 Overview - clutch actuation
Note
♦ Before disconnecting battery, obtain code for radio having anti-theft coding.
♦ With the ignition switched off, disconnect battery earth strap ⇒ Electrical system; Rep. gr. 27 .
♦ When re-connecting the battery, observe the paragraph ⇒ Electrical system; Rep. gr. 27 .
♦ Grease all bearing points and contact surfaces.
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
1. Clutch mechanism: repairs 13

Toledo 2013 ➤
I - Assembly overview - pedal

assembly ⇒ page 15 .
II - Assembly overview - hy‐
draulics (LHD) ⇒ page 18
III - Assembly overview - hy‐
draulics (RHD) ⇒ page 20
14 Rep. gr.30 - Clutch

Toledo 2013 ➤
1.2 Assembly overview - pedal cluster

⇒ “1.2.1 Assembly overview - pedal cluster (vehicles up to
MY16)”, page 15
⇒ “1.2.2 Assembly overview - pedal cluster (vehicles from
MY16)”, page 17
1.2.1 Assembly overview - pedal cluster (vehicles up to MY16)
1 - Bulkhead of the plenum

chamber
❑ With support for mount‐
ing bracket and master
cylinder
2 - Drift sleeve
❑ For upper mounting
hole in mounting brack‐
et
❑ The sleeves of the bot‐
tom hole of the mount of
the mounting bracket
are located on the clutch
cylinder
3 - Mounting bracket
❑ Removing and installing
clutch master cylinder
⇒ page 25
4 - Self-locking hexagon nut,
25 Nm
❑ 3 off
❑ Always replace
5 - Checking clutch pedal
switch - F36-
❑ Identification
⇒ page 24
⇒ page 24
6 - Crash bar
❑ Attached to steering col‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
umn permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Allocate components
using ⇒ Electronic parts
catalogue (ETKA)
7 - Plug
❑ 20 Nm
❑ Allocate components using ⇒ Electronic parts catalogue (ETKA)
8 - Stop
❑ For clutch pedal
9 - Bearing pin
❑ Always replace
10 - Clutch pedal
❑ Removing and installing with extension spring, LHD ⇒ page 30
❑ Removing and installing, RHD ⇒ page 33

Toledo 2013 ➤
11 - Mounting bush
12 - Extension spring with vibration damper
❑ Hooked into mounting bracket ⇒ Item 3 (page 15) and into clutch pedal
13 - Cap
❑ Renew only with master cylinder removed
❑ Removing ⇒ page 19
❑ Driving in ⇒ page 19
15 - Clutch master cylinder
❑ removing and installing ⇒ page 42
16 - Clip
❑ To remove and install pipe/hose assembly,
Protected by pullforout
copyright. Copying clip
private as far aspurposes,
or commercial it will ingo
part or in whole, is not
❑ Pulled out to side on some slave cylinders
17 - Seal
❑ Always replace
❑ Stick to master cylinder
18 - Supply hose
❑ Replace ⇒ Item 2 (page 18)
19 - Clutch position sender - G476-
❑ For vehicles with start stop system
❑ Installing ⇒ page 28
❑ This may be checked with the “Guided fault finding” using the vehicle diagnostic tester
Removing and installing extension spring

– Insert shock absorber with the recess -arrows- ill. 2 spring coil
-arrows-.

Toledo 2013 ➤
1.2.2 Assembly overview - pedal cluster (vehicles from MY16)
1 - Clutch pedal
❑ removing and installing
⇒ page 35
❑ Is not lubricated
2 - Sleeve bearing
⇒ page 37
⇒ page 43
4 - Clip
❑ Pull out clip to stop to re‐
move and install pipe/
hose line
5 - Seal
❑ Self-adhesive
❑ stick onto the master
cylinder
❑ replace after removing
the master cylinder
6 - Clutch position sender -
G476-
⇒ page 44
❑ Can be checked with the
⇒ Vehicle diagnostic
tester in the mode Gui-
ded Fault Finding
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
7 - Bearing pin
❑ replace after each removal
❑ is not lubricated
8 - Bulkhead
❑ with pin bolts for securing the bearing bracket for the clutch pedal and master cylinder
9 - Drift sleeve
❑ for upper mounting bolt
❑ The bushes for the lower fastening holes of the mounting bracket for the clutch are located in the master
cylinder
10 - Conical hexagon bolt
❑ Mounting bracket with clutch pedal and master cylinder on the front wall
❑ 3x
❑ Self-locking Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ replace after eachrespect
removal
to the correctness of information in this document. Copyright by SEAT S.A.
❑ 25 Nm
❑ For clutch pedal

Toledo 2013 ➤

12 - Over-centre spring
❑ In the mounting bracket for clutch pedal
❑ Lubricate with grease ⇒ Electronic Original Parts Catalogue .
13 - Sleeve bearing
14 - Bump stop
15 - Securing pin
❑ For the bearing bush of the master cylinder
❑ Replace after each removal
16 - Cap
1.3 Assembly overview - hydraulics (LHD)
1 - Brake fluid reservoir

2 - Supply hose
3 - Seal
❑ The seals must be loca‐
ted in supply hose
⇒ page 42
5 - Clip
❑ To remove and install
pipe/hose assembly,
pull out clip as far as it
will go
❑ Renew only with master
cylinder removed
7 - Mounting bracket with
clutch pedal
8 - Hexagonal nut
❑ ⇒ Item 4 (page 15)
9 - Seals / O-rings
❑ Pull onto line connection
❑ Lubricate with brake flu‐
id before installing
❑ Seals/O-rings are adap‐
ted to configuration of
line connection
⇒ page 19
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)

Toledo 2013 ➤
10 - Pipe and hose assembly

❑ Determine according to ⇒ Electronic parts catalogue (ETKA) .
❑ For removal, the ABS control unit must be removed along with the hydraulic unit ⇒ Brake system; Rep.
gr. 45
11 - Rear bracket
❑ Attached to body
12 - Hexagonal bolt
13 - Clip
❑ To remove and install pipe/hose assembly, pull out clip as far as it will go
14 - Bleeder valve
❑ Bleed the clutch system ⇒ page 46 .
15 - Closing cap
16 - Clutch slave cylinder
❑ removing and fitting ⇒ page 44
Levering retaining clip -A- off in direction of arrow
Carefully press the operating rod of the master clutch cylinder into
the mount -A-.
Seals and O-rings for pipe and hose lines

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

Toledo 2013 ➤
1.4 Assembly overview - hydraulics (RHD)
1 - Brake fluid reservoir

2 - Supply hose
3 - Seal
❑ The seals must be loca‐
ted in supply hose
⇒ page 42
5 - Clip
❑ Pull clip out to stop to re‐
move pipe/hose line
❑ Renew only with master
cylinder removed
7 - Mounting bracket with
clutch pedal
8 - Hexagonal nut Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ ⇒ Item 4 (page 15) respect to the correctness of information in this document. Copyright by SEAT S.A.
9 - Brake lines
❑ Various number
10 - Rear bracket
11 - Rear bracket
❑ For brake lines and
pipe/hose line
12 - Pipe and hose assembly
❑ Determine according to ⇒ Electronic parts catalogue (ETKA) .
13 - Seals / O-rings
❑ Pull onto line connection
❑ Lubricate with brake fluid before installing
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 19
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
14 - Hexagonal bolt
15 - Clip
❑ To remove and install pipe/hose assembly, pull out clip as far as it will go
16 - Bleeder valve
❑ Bleed the clutch system ⇒ page 46 .
17 - Closing cap

Toledo 2013 ➤
1.5 Clutch hydraulics (vehicles from MY16)

- assembly overview
⇒ “1.5.1 Clutch hydraulics (left-hand drive vehicles from MY16) -
assembly overview”, page 21
⇒ “1.5.2 Clutch hydraulics (right-hand drive vehicles from MY16)
- assembly overview”, page 23
1.5.1 Clutch hydraulics (left-hand drive vehicles from MY16) - assembly overview
1 - Bolt
❑ 20 Nm
2 - Vent valve
❑ Bleeding clutch mecha‐
nism ⇒ page 46
❑ 4.5 Nm
3 - Dust cap
4 - Supply hose
5 - Brake fluid deposit
6 - Seal
❑ must be located at the
return hose
⇒ page 43
8 - Clip
hose line
9 - Seals / O-rings
Parts
❑ Gasket rings/O-rings
are adapted to the ver‐
sion of the line connec‐
tion ⇒ page 22
❑ Replace if damaged
❑ fit onto the line connec‐
tion
❑ Fit with brake fluid Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
10 - Hose/pipe assembly respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ The shape of the hose pipe line may differ from the figure.
❑ Assignment ⇒ Electronic Catalogue of Original Parts
❑ removing and installing ⇒ “1.13 Removing and installing clutch mechanism lines”, page 39
11 - Bracket
❑ For pipe/hose assembly
❑ Gasket rings/O-rings are adapted to the version of the line connection ⇒ page 22
❑ fit onto the line connection

Toledo 2013 ➤
❑ Fit with brake fluid

13 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line
Disconnecting and connecting clutch cables

Cutting
– Release clips -3- using a screwdriver and pull off pipe line
-1- from line connection -4-.
Connecting
Note
♦ Instead of the seal -2-, an O-ring can also be installed

⇒ page 22 .
♦ Renew seal -2- if damaged.
– Press the pipe line -1- onto the line connection -4- until the
clips -3- audibly engage.
– Check for proper fastening by pulling on the line.
Seals/O-rings for pipes

Location Connection type
1 Connection with annular groove -arrow 1-
2 Connection with shoulder -arrow 2-
3 Line connection with shoulder -arrow 2- and cir‐
cumferential groove -arrow 3-
• A seal/O-ring must be used here on the connection with the
recess -arrow 1- and -arrow 3-

Toledo 2013 ➤
1.5.2 Clutch hydraulics (right-hand drive vehicles from MY16) - assembly over‐
view
1 - Bolt
❑ 20 Nm
⇒ page 44
3 - Gearbox:
4 - Seals / O-rings
Parts
❑ Gasket rings/O-rings
are adapted to the ver‐
sion of the line connec‐
tion ⇒ page 22
❑ fit onto the line connec‐
tion
❑ Fit with brake fluid Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Brake fluid deposit respect to the correctness of information in this document. Copyright by SEAT S.A.
6 - Seal
❑ must be located at the
return hose
7 - Supply hose
⇒ page 43
9 - Clip
hose line
10 - Bracket
❑ Secured to body
11 - Brake line
12 - Bracket
13 - Hose/pipe assembly
❑ removing and installing ⇒ “1.13 Removing and installing clutch mechanism lines”, page 39
❑ Gasket rings/O-rings are adapted to the version of the line connection ⇒ page 22
❑ fit onto the line connection
❑ Fit with brake fluid

Toledo 2013 ➤
15 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line
16 - Vent valve
❑ Bleeding clutch mechanism ⇒ page 46
❑ 4.5 Nm
17 - Dust cap
1.6 Clutch pedal switch - F36- : Removal /

installation and adjustment
So that it is correctly fitted in the clutch pedal bracket, the clutch
pedal switch - F36- should only be fitted once.
1.6.1 Removing clutch pedal switch

Detaching
– Remove the driver side foot well cover ⇒ Bodywork, interior
fitting work; Rep. gr. 68 .
– Removing footwell diffuser ⇒ Heating, Air conditioning; Rep.
gr. 80 .
Clutch pedal switch is installed above the plenum chamber bulk‐
head.
– Unplug connector from clutch pedal switch .
– Turn clutch pedal switch on mounting bracket 45° in
-direction of arrow- and pull out of support.
1.6.2 Installing clutch pedal switch

Distinguishing between clutch pedal switches
Identification of the clutch pedal switch
-A- = »without light dome« on • Pull plunger out fully prior to
plunger head -arrow- installation.
-B- = »with light dome« on • Plunger is not allowed to be

plunger head -arrow- pulled out.
• Grease plunger head.

• Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
• Clutch pedal must always remain in rest position when clutch
pedal switch is being installed. Clutch pedal is only allowed to
be touched with plunger head of clutch pedal switch during
entire installation procedure.

Toledo 2013 ➤
Clutch pedal switch is installed from bulkhead.

– Insert clutch pedal switch into mounting bracket support and
turn 45° in -direction of arrow-.
– Plug in connector for clutch pedal switch .
– Install the footwell diffuser ⇒ Heating, Air conditioning; Rep.
gr. 80 .
– Install the driver side foot well cover ⇒ Bodywork, interior fit‐
ting work; Rep. gr. 68 .
1.7 Removing and installing mounting

bracket
⇒ “1.7.1 Removing and installing mounting bracket with clutch
master cylinder (vehicles up to MY16) ”, page 25
master cylinder (vehicles from MY16)”, page 29
1.7.1 Removing and installing mounting bracket with clutch master cylinder (ve‐
hicles up to MY16)
Special tools and workshop

equipment required
♦ Choke clip for hoses -
3094-
♦ Torque wrenches - V.A.G
1331-
♦ Not required, spring-type
clip pliers - VAS 5024 A-

Toledo 2013 ➤
Sealing tool - T10249-

Removal:
Left-hand drive vehicle
– Then remove complete air filter housing if it is preventing ac‐
cess to master cylinder ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24 .
– Remove engine control unit from bulkhead if it is preventing
access to master cylinder ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24
Right-hand drive vehicles

In some vehicles, master cylinder is located behind a line for air
conditioning system -arrow-.
An insulation mat is installed in conjunction with some engines.

Appearance may be different from that illustrated.
– Remove the insulating element -arrows-.
Continuation for all vehicles

Toledo 2013 ➤
Note
♦ When performing the following operations described, care

must be taken not to spill brake fluid onto the sill or the gear‐
box. If this does happen, clean the affected area thoroughly.
♦ Place a lint-free cloth under the master cylinder.
– Clamp off supply hose to master cylinder using hose clamp -

3094- .
– Pull supply hose -1- off master cylinder.
– In addition, for disconnecting, you can close it with the sealing
tool - T10249/1- (⇒ figure above).
– Disengage the safety fastener -2- with a screwdriver or tipped
object, and uncouple the pipe and hose assembly -3- from the
clutch master cylinder.
Note
Securing clip -2- can also be pulled out to side in some master
cylinders.
Vehicles with start/stop system:

– Unclip clutch position sender - G476- on the clutch master
cylinder -arrow A- and -arrow B-.
– Remove the clutch position sender on the clutch master cyl‐
inder when the connector is closed.
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
When carrying out work in the footwell, the carpet must be pro‐
tected against brake fluid spillage using cloths.
– Remove the driver side lining ⇒ Bodywork, interior fitting work;

Rep. gr. 70
gr. 80 .
– If fitted, remove crash bar -arrow-.

– Remove clutch pedal switch - F36- ⇒ page 24 .

Toledo 2013 ➤
– Remove securing nuts -1- and -2-.

– Detach mounting bracket -3-.
Installing
Installation is carried out in reverse order, noting the following:
Note
♦ Apply new foam sealant to the mounting bracket and clutch

master cylinder.
♦ Renew self-locking nut.
– Install clutch pedal switch - F36- ⇒ page 24 .
– If fitted, install crash bar by tightening securing bolts -arrow-

to specified torque ⇒ Item 7 (page 15) .
gr. 80 .
– Install the driver side lining ⇒ Bodywork, interior fitting work;
Rep. gr. 70
Vehicles with start/stop system:

– Insert the clutch position sender - G476- up to the end of the
clutch master cylinder when the connector is closed.
• Clutch position sender must clip in -arrow A-.
– To check, pull on clutch position sender -arrow B-.
– After removing hose clamp - 3094- , return supply hose -1- to
its original position, if necessary.
– Press in pipe and hose assembly or plastic line -2- into the
slave clutch cylinder connection until safety fastener -2- is au‐
dibly secured.
– Test line by tugging on it.
– Hydraulic clutch system: bleeding of air ⇒ page 46 .
– If engine control unit was removed, fit it onto bulkhead ⇒ Rep.
gr. 23 or ⇒ Rep. gr. 24
– If necessary, mount the air filter housing ⇒ Rep. gr. 23 and
⇒ Rep. gr. 24 .

Toledo 2013 ➤
1.7.2 Removing and installing mounting

bracket with clutch master cylinder (ve‐
hicles from MY16)
Special tools and workshop equipment required
♦ Choke clip for hoses - MP7-602 (3094)-
♦ Sealing tool - T10249-
Removal:
– Disconnect battery ⇒ Electrical installation; Rep. gr. 27 .
– Remove engine control unit - J623- ⇒ Engine; Rep. gr. 24 .
– Remove the clutch position sender - G476- with connected
electrical plug connection from the master cylinder
⇒ “1.16 Removing and installing clutch position sender G476
”, page 44 .
MP7-602 - - A-.
In addition, after disconnecting, it can be sealed with the sealing
tool - T10249/1- -B-.
Note
♦ If the return hose with hose clamp - MP7-602 - is disconnected,

it will forever be deformed.
♦ However, this does not damage the supply hose.
♦ After the hose clamp - MP7-602 - is removed, the return hose
must be returned to its original form.
Caution
Risk due to leaking coolant.

♦ During the following work, ensure that no brake fluid lands
on longitudinal member or gearbox. If this does happen,
clean the affected areas thoroughly.
♦ Place a lint-free cloth under the clutch master cylinder.
♦ When working in the footwell, protect the floor carpet with
cloths from escaping brake fluid.
– Remove the return hose to the master cylinder -1-.
– Release clamp -2- using a screwdriver and pull off the supply
line -3- ⇒ page 22 .
– Seal openings.
– Remove drive shaft ⇒ Chassis, axles, steering; Rep. gr. 48 .

Toledo 2013 ➤
– Remove securing nuts -1- and -2-.

– Take out mounting bracket of the clutch pedal -3-.
Installing
Install in reverse order of removal; note the following.
– Renew after removing the retaining nuts and the seal of the
master cylinder.
– Install drive shaft ⇒ Chassis, axles, steering; Rep. gr. 48 .
– Connect line -3- at the connection in such a way that the clamp
-2- audibly engages ⇒ page 22 .
– Fit return hose -1- on the master cylinder.
• After the hose clamp - MP7-602 - is removed, the return hose
– Install clutch position sender - G476-
⇒ “1.16 Removing and installing clutch position sender G476
”, page 44 .
– Install the engine control unit with connected electrical plug
connection into the bracket on the front face ⇒ Engine; Rep.
gr. 24 .
– Bleed clutch mechanism ⇒ page 46 .
– Fit the battery ⇒ Electrical system; Rep. gr. 27 .
Tightening torques
♦ Bearing bracket for clutch pedal on front wall
MY16)”, page 17 .
♦ Crash strut to module carrier ⇒ Chassis, axles, steering; Rep.
gr. 48 .
1.8 Removing and installing clutch pedal

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

Special tools
permitted and
unless workshop
authorised by SEATequipment required
S.A. SEAT S.A does not guarantee or accept any liability with

Toledo 2013 ➤
♦ Pliers - T10005-
♦ Hooks - 3438-
♦ Allen key, 8 mm AF, commercially available
1.8.1 Detaching
– Remove the driver side lining ⇒ Bodywork, interior fitting work;
Rep. gr. 70
gr. 80 .
– Remove crash bar -arrow-.
– Remove clutch pedal switch - F36- ⇒ page 24 .
– Unhook extension spring.
Right-handrespect
part toofthefigure -arrows-
correctness onlyin applies
of information to Copyright
this document. installation.
by SEAT S.A.

Toledo 2013 ➤
– Release clutch master cylinder operating rod from clutch pedal

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

– To do this, turn bearing shaft for clutch pedal to left
-direction of arrow-.
-1- = Allen key, 8 mm AF.
Locking devices -A- are irreparably damaged.
Pins -B- are then horizontal.
– Move clutch pedal so you can pull out bearing shaft.
– Remove clutch pedal.
1.8.2 Installing
• Install clutch pedal with a new bearing shaft.
Grease extension spring supports.
– Make sure that support -2- is located on operating rod -1- of
clutch master cylinder.
– Place pins -A- horizontally.

– Turn bearing shaft to right -direction of arrow-.
• Locking devices -B- must audibly engage.
Pins -A- are then vertical.

Toledo 2013 ➤
– Hook in extension spring.

– Insert vibration damper with recess -arrows- from second
spring winding onwards -arrows-.
– Install clutch pedal switch - F36- ⇒ page 24 .
– Fit the anti-collision reinforcement. Tighten bolt -arrow- to

specified torque ⇒ Item 7 (page 15) .
gr. 80 .
– Install the driver side lining ⇒ Bodywork, interior fitting work;
Rep. gr. 70
1.9 Removing and installing clutch pedal,

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

♦ Pliers - T10005-

Toledo 2013 ➤
♦ Also for clutch pedal with return spring: Hook - 3438-
♦ Allen key, 8 mm AF, commercially available
1.9.1 Detaching
– Remove mounting bracket with master cylinder ⇒ page 25 .
– Release clutch master cylinder operating rod from clutch pedal
as described in the following:
– Press sides of retainer inwards -arrows- using pliers - T10005-
and pull gently on clutch pedal.
Clutch pedal with extension spring
– Unhook extension spring. (Shown here with mounting bracket
installed.)
Right-hand part of figure -arrows- onlyto applies to installation.
respect the correctness of information in this document. Copyright by SEAT S.A.
– Remove bearing shaft for clutch pedal.

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

Toledo 2013 ➤
1.9.2 Installing
• Insert clutch pedal with new bearing shaft.
– Place pins -A- horizontally.
– Turn bearing shaft to right -direction of arrow-.
• Locking devices -B- must audibly engage.
Pins -A- are then vertical.
– Set clutch pedal to rest position.
– Hook in extension spring. (Shown here with mounting bracket

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

– Press retainer into notch in clutch pedal -3- until it can be heard
to engage.
– Install mounting bracket ⇒ page 25 .
1.10 Removing and installing clutch pedal

(vehicles from MY16)

⇒ “1.10.1 Removing and installing clutch pedal (left-hand drive
vehicles from MY16)”, page 35
⇒ “1.10.2 Removing and installing clutch pedal (right-hand drive
vehicles from MY16)”, page 36
1.10.1 Removing and installing clutch pedal

(left-hand drive vehicles from MY16)
Removal:
– Slide driver seat as far back as possible.
– Set steering wheel as high as possible, using the entire ad‐
justment range of the steering column to do so.
– Remove the over-centre spring
⇒ “1.12 Installing and removing over-centre spring (vehicles
from MY16)”, page 38 .

Toledo 2013 ➤
– Turn pivot pins for clutch pedal using the socket bit (width
across flats 10) -1- all the way to the stop in
Note
The locking pieces -A- will be destroyed upon rotation.
– To remove the pivot pin, move the clutch pedal.

Installing
– Press the clutch pedal and insert new pivot pins all the way to
the stop.
• The catches -A- must audibly engage.
– Fit the over-centre spring
1.10.2 Removing and installing clutch pedal

(right-hand drive vehicles from MY16)
Removal:
– Remove mounting bracket
master cylinder (vehicles from MY16)”, page 29 .
– Press the catches -arrows- and detach the carrier bolt -1- of
the tappet for master cylinder to the right (shown with bearing
bracket installed).
– Lift clutch pedal to the stop toward the vehicle interior.
– Take out over-centre spring.

Toledo 2013 ➤
Note
The locking pieces -A- will be destroyed upon rotation.
– To remove the pivot pin, move the clutch pedal.

Installing
– Press the clutch pedal and insert new pivot pins all the way to
the stop.
• The catches -A- must audibly engage.
– Install mounting bracket
Tightening torques
♦ Mounting bracket to bulkhead
MY16)”, page 17 .
1.11 Installing and removing bearing bush

(vehicles from MY16)
Removal:
– Disconnect
Protected battery
by copyright. Copying earthorstrap
for private ⇒ purposes,
commercial Electrical system;
in part or in whole,Rep.
is not gr.
permitted27 . authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
unless
– Remove the over-centre spring
– Turn the plunger of the master cylinder until the recesses -1-
or the pin -2- are visible.
• Recesses -1- and pin -2- are facing the same direction.
– Remove bearing bush -A- from recesses -1-.
Installing

Toledo 2013 ➤
– Turn the plunger of the master cylinder until the recesses -1-
or the pin -2- are visible.
• Recesses -1- and pin -2- are facing the same direction.
– Guide bearing bush -A- into the recesses -1- and bring it into
the proper assembly position.
1.12 Installing and removing over-centre

spring (vehicles from MY16)
Removal:
– Slide driver seat as far back as possible.
– Set steering wheel as high as possible, using the entire ad‐
justment range of the steering column to do so.
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Press locking elements -arrows- and pull the securing pincorrectness
respect to the -1- of information in this document. Copyright by SEAT S.A.
to the right from the plunger of the master cylinder.
– Take out over-centre spring.
Installing
– Insert the over-centre helper spring lengthways from the bot‐

tom into the support -A- in the bracket next to the tappet of the
master cylinder and next to the clutch pedal.
• The partial area of the mount -arrow- for the mounting lug of
the clutch pedal must be positioned vertically.

Toledo 2013 ➤
– Press over-centre spring onto mounting lug of clutch pedal

-arrow-.
• The over-centre spring must sit directly in the lug -arrow 1- of

the mounting bracket to be able to properly guide it into the
clutch pedal -arrow 2- (⇒ also previous figure).
• Otherwise, the securing pin for the plunger/master cylinder
-1- cannot be installed (⇒ next figure).
– Press on the clutch pedal such that a new securing pin -1- for
the plunger/master Protected
cylinder can beCopying
by copyright. guided in uporto
for private the stop.
commercial purposes, in part or in whole, is not
• The locking pieces -arrows-
respect toof
thethe securing
correctness pin -1-in must
of information snapCopyright by SEAT S.A.
this document.
into place.
1.13 Removing and installing clutch mecha‐

nism lines
♦ Choke clip for hoses - MP7-602 (3094)-
Removal:
– Remove the complete air filter housing if the cables for the
clutch control are not accessible ⇒ Engine; Rep. gr. 24 .
– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .
– Remove the engine control unit with connected electrical plug
connection from the bracket on the front face and place to one
side ⇒ Engine; Rep. gr. 23 .

Toledo 2013 ➤
Right-hand drive vehicle

For certain engines, an insulation mat is installed (appearance
may differ from the figure).
– Remove washer -4-.

– Loosen the insulation mat at points -1, 2 and 3- in succession
and take out from above.
Continued for all versions

MP7-602 - .
Note
♦ If the return hose with hose clamp - MP7-602 - is disconnected,

it will forever be deformed.
♦ However, this does not damage the supply hose.
♦ After the hose clamp - MP7-602 - is removed, the return hose
Caution
Risk due to leaking coolant. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ During the following work, ensure that no brake fluid lands

on longitudinal member or gearbox. If this does happen,
clean the affected areas thoroughly.
♦ Place a lint-free cloth under the clutch master cylinder.
♦ When working in the footwell, protect the floor carpet with
cloths from escaping brake fluid.

Toledo 2013 ➤
– Unlock the clip on the connection -1- with a screwdriver and

remove the feed hose line ⇒ page 22 .
– Seal openings.
– Pull out the clip -A- up to the stop and detach the hose line
-B- ⇒ page 22 .
– Seal openings.
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Seal off open lines and connections if necessary with clean plugs
from engine bung set - VAS 6122- .
– Loosen tube line and remove.

Installing
– Connect the hose line -1- with connector to the master cylinder
and to the slave cylinder ⇒ page 22 .
• After removing the hose clamp - 3094- , it may be necessary
to bring the return hose -2- back into its initial position.
connection into the bracket on the front face ⇒ Engine; Rep.
gr. 23 .
– If present, fasten the insulation mat at points -1, 2 and 3-.

– Fasten insulation mat using the washer -4-.
– Bleed clutch mechanism ⇒ page 46 .
– Install the battery tray and battery ⇒ Electrical System; Rep.
gr. 27 .
– Install the complete air filter housing if it was removed ⇒ En‐
gine; Rep. gr. 24 .

Toledo 2013 ➤
1.14 Removing and installing clutch master

cylinder
⇒ “1.14.1 Removing and installing clutch master cylinder (vehi‐
cles up to MY16)”, page 42
⇒ “1.14.2 Removing and installing clutch master cylinder (vehi‐
cles from MY16)”, page 43
1.14.1 Removing and installing clutch master

cylinder (vehicles up to MY16)
♦ Pliers - T10005-
Removal:
– Remove the mounting bracket along with the master clutch
cylinder ⇒ page 25 .
– Release clutch pedal from master cylinder with pliers -
T10005- .
– Remove the clutch master cylinder from the bearing block.
Levering retaining clip -A- off in direction of -arrow-
Carefully press the actuator rod/master cylinder in the support

-A-
Installing
– Remove the clutch master cylinder from the mounting block.

Toledo 2013 ➤
– Make sure that support -1- is located on operating rod -2-.

• Ensure that the support -2- is located on the actuator rod -1-.
Note
If the support -2- was removed it will need to be installed first

⇒ page 42
– Press the support -2- into the recess on the clutch pedal -3-
until it clicks audibly into place.
– Install mounting bracket with master cylinder ⇒ page 25 .
1.14.2 Removing and installing clutch master

cylinder (vehicles from MY16)
Removal:
– Remove mounting bracket of the clutch pedal with master cyl‐
inder
– Press the locking elements of the securing pin -1- of the master
cylinder plunger -arrows- (shown with installed mounting
bracket).
– Pull out securing pin for plunger/master cylinder from the

clutch pedal -arrow A-.
The master cylinder is mounted with fasteners -arrows B- on the
mounting bracket
Protected of the clutch
by copyright. pedal.
Copying for private or commercial purposes, in part or in whole, is not
Only 2 of the 4 respect

fasteners -arrowsofB- are shown in the Copyright
figure.by SEAT S.A.
to the correctness information in this document.
– Loosen fasteners -arrows B- and pull out master cylinder from

the mounting bracket of the clutch pedal.
Installing
• After removal, renew the securing pin -arrow A- (⇒ top figure).
• The locking pieces of the securing pin must engage.
– To check for proper latching, pull lightly on the securing pin.
– Insert master cylinder into the mounting bracket of the clutch
pedal -arrow B- (⇒ top figure) until all fastening pieces are en‐
gaged.
– To check for proper seating, pull on the master cylinder.
– Install clutch pedal mounting bracket

Toledo 2013 ➤
1.15 Removing and installing clutch slave

cylinder
♦ Torque wrench - V.A.G 1331-
1.15.1 Detaching
– The filter must be removed if there is no permitted
access to the
unless slaveby SEAT S.A. SEAT S.A does not guarantee or accept any liability with
authorised
cylinder ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24 . respect to the correctness of information in this document. Copyright by SEAT S.A.
– Fit a lint-free cloth under the clutch slave cylinder.
– Remove the safety fastener -A- which secures the hose and
pipe assembly from the clutch slave cylinder up to the limit.
– Remove the pipe and hose assembly from the casing -C-.
– Remove the hose and pipe assembly -B- from the clutch slave
cylinder and close it.
– Remove bolts for slave cylinder -arrows- and remove slave
cylinder.
Caution
Do not operate clutch pedal after disconnecting pipe/hose as‐

sembly.
1.15.2 Installing
– Bolt slave cylinder to gearbox -arrows- ⇒ Item 12 (page 19) .
– Insert pipe/hose line -B- into slave cylinder to stop.
– Press in clip -A- onto stop.
– Press pipe/hose line into support -C- on gearbox.
– Bleed the clutch circuit after installing slave cylinder
⇒ page 46 .
– If the air filter has been removed, it has to be re-installed now
⇒ Rep. gr. 23 or ⇒ Rep. gr. 24 .
1.16 Removing and installing clutch position

sender - G476-

Toledo 2013 ➤
♦ Hook - 3438-
Removal:
– Disconnect battery ⇒ Electrical installation; Rep. gr. 27 .
– Remove the engine control unit with connected electrical plug
connection from the bracket on the front face and place to one
side ⇒ Engine; Rep. gr. 23 .
For certain engines, an insulation mat is installed (appearance
may differ from the figure).
– Remove washer -4-.

– by
Protected Loosen
copyright.the insulation
Copying mat
for private or at points
commercial -1,in2part
purposes, and or in3- in succession
whole, is not
and
permitted unless take
authorisedout from
by SEAT S.A.above.
SEAT S.A does not guarantee or accept any liability with
– Loosen locking piece -arrow A- of the clutch position sender -

G476- using the hook - 3438- .
– Press clutch position sender - G476- in -direction of arrow B-,
pull out from the retainer in the master cylinder and disconnect
electrical connector.
Installing

Toledo 2013 ➤
– Insert clutch position sender - G476- into master cylinder with

electrical connector connected. Push it in as far as stop.
• The locking piece of the clutch position sender - G476- must
engage -arrow A-.
– To check for proper seating, pull the clutch position sender -
G476- in -direction of arrow B-.
Note
Disregard items -1-, -2- and -3-.

connection back into the bracket on the front face ⇒ Engine;
Rep. gr. 23 .
– If present, fasten the insulation mat at points -1, 2 and 3-.

– Fasten insulation mat using the washer -4-.
1.17 Bleeding clutch system

♦ Brake filling and bleeding unit - VAS 5234-

Toledo 2013 ➤
Note
♦ The clutch mechanism must be bled after performing work on

the hydraulic system.
♦ During the following work, ensure that no brake fluid lands on
longitudinal member or gearbox.
♦ Prefilling the system is not necessary.
♦ Before bleeding, fill the brake fluid reservoir with brake fluid up
to the “max.” mark.
♦ Clutch pedal is at rest position, is not being depressed..
♦ Brake fluid: allocation ⇒ Electronic Parts Catalog .
Vehicles up to MY16
– If the slave cylinder is not accessible, remove the complete air
filter housing ⇒ Engine; Rep. gr. 24 .
– Connect the brake filling and bleeding device - VAS 5234- .
– Connect bleeder hose to bleeder valve -arrow-.
To bleed system, use the bleeder hose - V.A.G 1238/B3- (670
mm long) if necessary.
For vehicles from MY16
– Remove air filter housing when the air bleed valve is not ac‐
cessible -arrow- ⇒ Engine; Rep. gr. 24 .

Toledo 2013 ➤
– Remove the cap from the air bleed valve and connect the
brake filling and bleeding device - VAS 5234- or -arrow-.
To bleed system, use 670 mm bleeder hose - V.A.G 1238/B3- if
necessary.
– Then connect ventilation hose with the drip bottle of the brake
bleeding device.
– Connect the brake filling and bleeding device .
• Operating pressure 2.0 bar
– Open bleeder valve.
– Allow approx. 100 cm3 of brake fluid to run out.
– Close venting valve.
– Rapidly operate pedal from stop to stop 10 to 15 times.
– Open bleeder valve.
– Allow approx. 50 cm3 of brake fluid to run out.
– Close venting valve.
– Depress clutch pedal several times after completion of bleed‐
ing process.
Tightening torque
♦ Breather valve
⇒ “1.3 Assembly overview - hydraulics (LHD)”, page 18
♦ Breather valve
⇒ “1.5 Clutch hydraulics (vehicles from MY16) - assembly
overview”, page 21

Toledo 2013 ➤
2 Clutch release assembly - Installation overview
1 - Release bearing
❑ Remove and install to‐
gether with clutch re‐
lease lever
and guide sleeve
⇒ page 50 to
⇒ page 50
❑ Do not wash out bear‐
ing; wipe clean only
❑ Renew noisy bearings
2 - Bolt
❑ 5 Nm + 90°
❑ Always replace
3 - Clutch release lever:
❑ Remove and install to‐
gether with clutch re‐
lease collar Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ Item 1 (page 49) and respect to the correctness of information in this document. Copyright by SEAT S.A.
guide sleeve
⇒ page 50 to
⇒ page 50
❑ Remove any traces of
grease
4 - Retaining spring
❑ Secure to clutch release
lever
5 - Guide bushing
together with clutch re‐
lease collar
⇒ Item 1 (page 49) and
clutch release lever
⇒ Item 3 (page 49) ⇒ page 50 to the ⇒ page 50
6 - Join ring for the input shaft
❑ Replace ⇒ Item 2 (page 108)
7 - Ball head stud, 20 Nm
❑ Remove old grease from contact surface of clutch release lever
❑ Lubricate with grease -G 000 100-
8 - Gearbox
9 - Hexagon bolt, 20 Nm
2. Clutch release assembly - Installation overview 49

Toledo 2013 ➤
Removing and installing clutch release lever with release bearing

and guide sleeve
– Screws out bolts -arrows-.
– Remove clutch release lever using the clutch release collar
and input shaft and knuckle pin guide sleeves.
Installation is carried out in the reverse order.
Removing and assembling the guide sleeve

– Detach the guide sleeve -3- from the clutch release collar -2-
by pressing upwards.
– Rotate guide sleeve -3- about 90º in the direction of the arrow
in relation to the clutch release collar -2- until the tabs of the
guide sleeve are in the recesses -4- of the clutch release collar.
– In this position, extract the guide sleeve for the clutch release
bearing.
Installation is carried out in the reverse order.
Removing and installing release bearing

– Press locking lugs -arrows- together on reverse side of clutch
release lever and remove release bearing -A- from clutch re‐
lease lever.
– For the installation, the clutch release collar -A- must be press‐
ed onto the clutch release lever until the tabs -arrows- engage.

Toledo 2013 ➤
3 Clutch: repairing

equipment required
♦ retention tool - 3067-
♦ Centring mandrel. -
T10086-
♦ Torque wrench -
V.A.G 1331-
♦ Grease for clutch plate
splines - G 000 100-
Note
♦ Check if the centring sleeves are installed in the engine for the purpose of centring the engine with the
gearbox and insert these if they are not installed.
♦ If the dowel sleeves are not fitted, this will lead to gear-change problems, clutch malfunction and in some
cases gearbox noise (gears will make rattling noises).
♦ Always replace clutch disks and pressure plates with damaged or loose rivet connection.
♦ Corresponding to ⇒ Electronic catalogue of spare parts“ETKA”
3. Clutch: repairing 51
Toledo 2013 ➤
1 - Flywheel
❑ Make sure that the cen‐
tring pins have a tight fit.
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
⇒ Rep. gr. 13
2 - Clutch plate
❑ Assignment according
to ⇒ Electronic parts
catalogue “ETKA”
❑ Installation location:
spring cage is aligned to
pressure plate Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Centralising respect to the correctness of information in this document. Copyright by SEAT S.A.
⇒ page 53
❑ Lightly grease splines
Note
Clean input shaft splines and, on

used clutch plate, hub splines. Re‐
move corrosion and apply only a
very thin coat of grease - G 000 100-
to input shaft splines. Then move
the clutch plate on the input shaft
from side to side, until the hub
moves smoothly on the shaft. Ex‐
cess grease must be removed.
3 - Pressure plate
⇒ page 53
❑ Checking ends of dia‐
phragm spring ⇒ page 53
Note
The pressure plates are greased

and protected against corrosion.
Clean contact surface only; other‐
wise the service life of the clutch will
be considerably reduced.
4 - Bolts M 6, 13Nm, Bolts M 7, 20 Nm

❑ Corresponding to ⇒ Electronic catalogue of spare parts“ETKA”
❑ Loosen or tighten diagonally in small steps

Toledo 2013 ➤
Central clutch disk and remove and install the pressure plate
– Loosen or tighten bolts diagonally in stages.
– Reverse position of counterhold tool - 3067- when removing.
Note
The contact surfaces of the pressure plate and the clutch plate
must rest entirely on the flywheel. Tighten the fixing bolts equally
and diagonally, so as to avoid damaging centring holes of pres‐
sure plate and centring pins of the flywheel.
Check ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring is per‐
mitted.
3. Clutch: repairing 53
Toledo 2013 ➤
34 – Controls, housing
1 Gear mechanism: repairing
⇒ “1.1 Installation position - selector mechanism”, page 54
⇒ “1.2 Overview of selector mechanism”, page 55
⇒ “1.3 Assembly overview - gear knob and cover”, page 56
⇒ “1.4 Removing and fitting the gear lever knob and cover”, page
56
⇒ “1.5 Gear lever and protective housing: repairs”, page 57
⇒ “1.6 Gear selection mechanism cables: removing and fitting;
general overview”, page 60
⇒ “1.7 Gearbox mechanism: removing and fitting”, page 64
⇒ “1.8 Gear drive mechanism: adjustment”, page 66
1.1 Installation position - selector mechanism

Gear movement -arrow A-
Selection movement -arrow B-
A - Gear selector cable

B - Selection control cable
C - Heat shield
❑ Remove before remov‐
ing selector mecha‐
nism.
1 - Gear lever
2 - Return lever
54 Rep. gr.34 - Controls, housing

Toledo 2013 ➤
1.2 Overview of selector mechanism
Note
♦ Note radio code for vehicles with coded radio.

♦ Disconnect earth strap at battery before carrying out work on the shift mechanism in the engine compartment
⇒ Electrical system; Rep. gr. 27 .
♦ When re-connecting the battery, the work that has to be carried out subsequently must be considered ⇒
Electrical system; Rep. gr. 27 .
♦ For work on selector mechanism in engine compartment, remove complete air filter housing if it is located
over selector mechanism ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24
♦ Remove selector mechanism to renew selector cables ⇒ page 64 .
♦ Do not kink selector cables.
I - Assembly overview - gear

knob and cover ⇒ page 56
II - Repairing gear lever and
selector housing ⇒ page 57
III - Assembly overview - re‐
moving and installing selector
cables ⇒ page 60 .
Removing and installing selector mechanism ⇒ page 64

Adjust selector mechanism ⇒ page 66 .
1. Gear mechanism: repairing 55

Toledo 2013 ➤
1.3 Assembly overview - gear knob and cover
1 - Emblem
❑ Can be carefully levered
off gear knob of plastic
or leather
2 - Gear knob
❑ With gaiter
❑ Gear knob and gaiter
cannot be separated
from one another
❑ Always renew together
⇒ page 56
3 - Clamp
❑ To fix knob onto gear
lever
❑ Always replace
❑ Secure to gear knob us‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ing hose clip pliers - permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
V.A.G 1275- respect to the correctness of information in this document. Copyright by SEAT S.A.
4 - Cover of central console

❑ Combined with upper
part of centre console in
one part
❑ Individual in some
equipment versions
5 - Damper
❑ Not fitted in all vehicles
❑ Arrow on noise insula‐
tion points in direction of
travel
❑ Locking lugs are ar‐
ranged at varying inter‐
vals
❑ Therefore it can be installed in only one position
1.4 Removing and fitting the gear lever knob

and cover
♦ Removal wedge - 3409-

Toledo 2013 ➤
♦ Hose clip pliers - V.A.G 1275 A-
Detaching
– Undo the dust guard with the removal wedge - 3409- by lev‐
ering alternately from both side -arrows- and then removing it
upwards.
– Pull gaiter upwards, inside out over gear knob.
– Open clamp -arrow- and pull off gear knob together with gaiter.
Installing
– Turn dust cover over.
The gear knob must be pressed to stop.
– Install gear knob and gaiter and squeeze new clamp -arrow-
together.
1.5 Gear lever and protective housing: re‐

pairs

Toledo 2013 ➤
♦ Assembly tool - T10236-
Note
♦ Lubricate bearing positions and sliding surfaces.

1 - Retainer washer
❑ The compression spring
must be pressed down
for the removal and in‐
stallation
2 - Compression spring
3 - Seal
❑ Always replace
❑ Between gear lever cas‐
ing and vehicle under‐
body
❑ Self-adhesive
❑ Bond to selector hous‐
ing
4 - Gear lever
5 - Damper
⇒ page 59
6 - Lever protection box
7 - Damping washer
❑ Must be located in
groove -arrows- in gear
lever
8 - Seal
❑ Always replace
9 - Lower plate
❑ To disassemble, open
the tabs
❑ Always replace
10 - Drift sleeve
11 - Selection control cable
❑ Pry off using release tool - T10236-
❑ Install in the gate selector lever of the gear selection mechanism

Toledo 2013 ➤
❑ Installation position ⇒ page 54

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

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

Toledo 2013 ➤
1.6 Gear selection mechanism cables: removing and fitting; general overview
Note
♦ Lubricate bearing positions and sliding surfaces.

1 - Gear selector cable

❑ Connect to cable end-
piece
❑ Installation position
⇒ page 54
2 - Selection control cable
❑ Connect to cable end-
piece
⇒ page 54
3 - Drift sleeve
4 - Retainer washer
❑ Always replace permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Do not damage the ca‐ respect to the correctness of information in this document. Copyright by SEAT S.A.
bles when disassem‐

bling
5 - Lever protection box
6 - Cable support bracket
7 - Sleeve
❑ Cable support bracket
mounting on gearbox
8 - Spacer
9 - Hexagon bolt, 25 Nm
❑ 3 off
❑ For cable support brack‐
et
10 - Cable end-piece
❑ After installing, adjust
selector mechanism
⇒ page 66
❑ To secure selection control cable to relay lever
❑ Remove from relay lever ⇒ page 63
❑ Press onto relay lever ⇒ page 63
❑ Allocation ⇒ page 61
11 - Retainer washer
❑ Always replace
12 - Cable end-piece
❑ After installing, adjust selector mechanism ⇒ page 66
❑ For gear selector cable to gearbox selector lever
❑ Allocation ⇒ page 61

Toledo 2013 ➤
13 - Self-locking hexagon nut, 25 Nm

❑ Always replace
14 - Gear lever
❑ Can be replaced with the gearbox drive mechanism in place
15 - Sliding piece
16 - Return lever
❑ Remove and install together with cable end-piece ⇒ page 62
17 - Wiring clip
❑ For relay lever
Allocation of cable end-pieces

The holes in the cable end-pieces have different
Protected diameters.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
Cable end-piece for: Gapto“a”
respect the correctness of information in this document. Copyright by SEAT S.A.
1 - Gear selector cable to 8.5 mm

gearbox selector lever
2. - Gate selector cable to 10 mm
relay lever
Fit the idler rod

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

Toledo 2013 ➤
Installation position of gearbox selector lever and relay lever

1- Gear lever
2- Relay lever engages in guide rail of gearbox selector lever
via shoe -arrow-.
Removing and installing relay lever with cable end-piece

• Cable end-piece must be detached from gate selector cable
before removing relay lever.
This will avoid damage to the gate selector cable.
• The cable end-piece can be removed only with the relay lever
removed ⇒ page 63 .
– Pull locking mechanism forwards in direction of -arrow 1- onto
stop and then turn to left in direction of -arrow 2- to lock.
– Then press relay lever forwards (in direction of -arrow 3-).
The relay lever is secured with a catch -arrow 1- in the cover

– Carefully press down the catch -arrow 1- up to the stop.
– Then move relay lever back and forward in its bearing (direc‐
tion of operation). To do so, carefully pull out the relay lever
together with the cable lock -arrow 2-.
• Only remove the cable lock -arrow 2- on removed relay lever
⇒ page 63 .
Note
To install, grease bearing points and contact surfaces with grease

⇒ Electronic catalogue of original parts .
– Press cable end-piece onto relay lever ⇒ page 63 .

– Insert relay lever together with cablepermitted
end-piece.
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
• Clip -arrow 1- secures the relay lever.
• The cable lock must be located behind the catch -arrow 2-.

Toledo 2013 ➤
– Remove the clip -arrow 1- and remove the relay lever together
with the fixing elements of the cable.
The fixing elements of the cable must be located behind the de‐
tent -arrow 2-.
Note
♦ When installing, lubricate bearing positions and sliding surfa‐

ces.
– Press cable end-piece onto relay lever ⇒ page 63 .

– Insert relay lever with cable end-piece as far as stop.
• Clip -arrow 1- secures the relay lever.
• Check that it is fitted securely.
• The fixing elements of the cable must be located behind the
detent -arrow 2-.
Levering cable end-piece for gate selector cable off relay lever
• Relay lever is removed.
– Insert a flat-blade screwdriver -A- between bush -B- and relay
lever.
Press cablepermitted
end-pieces ontoCopying
Protected by copyright. relay for
lever
private or commercial purposes, in part or in whole, is not
• Relay lever isrespect
removed.
• Cable end-piece may be pressed only onto bush -arrow-.

• Cable end-piece must move freely on relay lever.
• It must be located behind catch -arrow 2- ⇒ page 62 .

Toledo 2013 ➤
1.7 Gearbox mechanism: removing and fit‐

ting
⇒ “1.7.1 Detaching”, page 64
⇒ “1.7.2 Installing”, page 66
⇒ “1.7.3 Specified torques”, page 66
1.7.1 Detaching
♦ Hose clip pliers - V.A.G 1275 A-
– First the vehicle

Protected should
by copyright. Copyingbe
forchecked if a coded
private or commercial radio
purposes, is installed.
in part or in whole, is not
If necessary
respect toobtain radioof anti-theft code first.Copyright by SEAT S.A.
the correctness information in this document.
– With the ignition switched off, disconnect battery earth strap

and remove the battery with console ⇒ Electrical system; Rep.
gr. 27 .
– If the air filter is situated behind the battery, it must be removed
⇒ Rep. gr. 23 or ⇒ Rep. gr. 24 .

Toledo 2013 ➤
– Remove safety washer -1-.

– Remove the selector lever cable from the pivot -2-.
– Undo the attachment element on the gear selector relay lever

-3- from the gate selector cable.
– Pull locking mechanism forwards in direction of -arrow 1- onto
stop and then turn to left in direction of -arrow 2- to lock.
– Then press relay lever forwards (in direction of -arrow 3-).
– Remove the control cable counter supports from the gearbox

-arrows-
Gearbox selector lever and relay lever with cable end-pieces are
shown removed for clarity of illustration. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove the dust guard from the centre console
respect frame using of information in this document. Copyright by SEAT S.A.
to the correctness
the removal wedge - 3409- , ⇒ page 56 .
– Then destroy clamp -arrow- and pull off gear knob with gaiter.
– If noise insulation is present, remove it.
– Remove the centre console with fixing bracket ⇒ Bodywork,
interior fitting work; Rep. gr. 68 .

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– Remove nuts for selector housing from body -arrows-.

– If insulation tray is installed below engine and gearbox, re‐
move it.
– Remove cross-section of the tunnel and separate exhaust
system ⇒ Rep. gr. 26 ; Exhaust system .
– Remove underbody trim ⇒ General body repairs, exterior;
Rep. gr. 50 .
– Swing selector housing down and remove with selector ca‐
bles.
1.7.2 Installing
– Spread a small amount of grease on pin of gearbox selector
lever. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Allocate grease using ⇒ Electronic parts
respectcatalogue (ETKA)
to the correctness . in this document. Copyright by SEAT S.A.
of information
– Renew securing clip -1- each time it is removed.

– Secure the connection cable -2- with the safety washer -1-.
– The gear selector relay lever -3- and the fixing element of the
cable must be mounted together ⇒ page 62 .
– Insert the selector cable in the fastening element.
– Install centre console ⇒ Bodywork, interior fitting work; Rep.
gr. 68 .
– Renew clamp -arrow-.

– Remove underbody trim ⇒ General body repairs, exterior;
Rep. gr. 50 .
– Mount the cross-section of the tunnel and front section of the
exhaust system ⇒ Rep. gr. 26 ; Exhaust system .
Adjust selector mechanism ⇒ page 66 .
– Install complete air filter housing ⇒ Rep. gr. 23 or ⇒ Rep. gr.
24
– Observe the procedures after connecting the battery ⇒ Elec‐
trical system; Rep. gr. 27 .
1.7.3 Specified torques

Selector housing to body ⇒ Item 13 (page 59)
Selector cable support bracket to gearbox ⇒ Item 9 (page 60) .
1.8 Gear drive mechanism: adjustment

⇒ “1.8.1 functioning”, page 69

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

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

• Angled rod for fixing selector shaftrespect
and securing mechanism
for gear selector cable and gate selector cable must be ac‐
cessible.
– Remove the air filter if the bracket for securing the selector
shaft lever and the safety mechanism of the gearshift and se‐
lection control cable cannot be accessed ⇒ Rep. gr. 23 or ⇒
Rep. gr. 24
– Pull locking mechanisms on gate selector cable and gear se‐
lector cable end-pieces forward to stop -direction of arrow 1-
and then turn to left to lock -direction of arrow 2-.

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Secure selector shaft as follows:

– Press selector shaft down (direction of -arrow 1-).
– When pressing in the selector shaft, the bracket -A- must be
turned in the direction of -arrow 2-. In doing so, it must be
pressed in carefully at the same time until the selector shaft
engages.
– Remove the dust guard and, where applicable, the noise in‐
sulation of the centre console frame using the wedge - 3409- ,
⇒ page 56 .
– If noise insulation is present, remove it.
Now lock the gear lever as follows:
– Place the gearshift lever in neutral position.
– Guide locking pin - T10027 A- through hole -A- into hole -B-.
– Check that gate and selector cables -B- are inserted, free of
tension, into locking devices -A-.
– Now turn locking mechanisms on gear selector cable and gate
selector cable end pieces clockwise to stop
-direction of arrow 1-.
The spring presses the locking mechanism into original position
-direction of arrow 2-.
– Turn the bracket -A- until it has returned to its original position,
in the direction of the -arrow-.
Note
The angled rod -A- must be pressed out of selector housing to

stop and point straight up.

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

– If noise insulation was present, install it.
– Press gaiter into console.
– Ensure that the selector shaft can move freely.
– Re-install the complete air filter housing if it has been removed
⇒ Rep. gr. 23 or ⇒ Rep. gr. 24
1.8.1 functioning
• With gearbox in neutral, gear lever must rest in gate for 3rd
and 4th gear.
– Engage clutch.
– Select all gears several times. Pay particular attention to op‐
eration of reverse gear lock.
– If the difficulty in engaging a gear persists after repeated at‐
tempts, repeat adjustment procedure of selector mechanism
⇒ page 66 .

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2 Gearbox : removing and fitting

⇒ “2.1 Removing gearbox”, page 71
⇒ “2.2 Installing gearbox”, page 76
⇒ “2.3 Specified torques”, page 80

equipment required
♦ Support. - 10 - 222 A-
♦ Do not us the support de‐
vice 10 222A/8 for the 02R
gearbox
♦ Gearbox support assembly
- 3282-
♦ Adjustment plate - 3282/31-
♦ Support elements for gear‐
box (determine when set‐
ting adjustment plate on
gearbox support )
♦ Gearbox lifting tackle -
3336- for transporting gear‐
box
♦ Engine bracket supplement - 10 222A/31-

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♦ Engine bracket, basic set - T40091-
♦ Torque wrenches -
V.A.G 1331-
V.A.G 1332-
♦ Engine/gearbox jack -
V.A.G 1383 A-
♦ Grease for clutch plate
splines - G 000 100-
♦ Allocate grease using ⇒
Electronic parts catalogue
(ETKA) .
2.1 Removing gearbox

– The vehicle should be checked if a coded radio is fitted in the
vehicle. If necessary obtain radio anti-theft code first.
– Remove the air filter housing completely if it is located above
the gearbox ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24 .
– Remove the battery as well as its cover and mount ⇒ Electrical
system; Rep. gr. 27 .
2. Gearbox : removing and fitting 71

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– If the lifting eyes of the engine for support bracket - 10 - 222

A- are covered by a component, for example the air filter, it
must be removed now. ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24 .
– Remove plenum chamber cover ⇒ Rep. gr. 66 .
– Remove securing clip -arrow 1- for gear selector cable from
gearbox selector lever -B-.
– Remove the connector cable from the pivot.
– Remove the relay lever -A- together with cable end-piece
⇒ page 62 .
– Remove gearbox selector lever -B- by removing nut
-arrow 2-.
– Remove the control cable counter supports from the gearbox

-arrows-
– Tie up the connection and selection cables.
– Pull line between master and slave cylinders -A- out of support
-B-, if present, on gearbox.
– Remove slave cylinder -arrows-, lay to side and secure. Do
not disconnect pipes.
Caution
Do not operate clutch pedal after disconnecting pipe/hose as‐

sembly.
Vehicles with start / stop system

– Unplug the connector -arrow- from the gearbox neutral posi‐
tion sender - G701- .
– Remove the control cables of the starter ⇒ Electrical system;
Rep. gr. 27 .
– Then remove upper securing bolt from starter.
– Unscrew the upper bolts that secure the engine to the gearbox.
– Remove foam pieces or seal from upper edge of left and right
wings ⇒ Body, front; Rep. gr. 50 .

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Preparing the engine bracket supplement - 10 222A/31-4- :

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

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

1- attachment tool - 10-222 A /31-2-
2- Adapter - T40091/3-
3- attachment tool - 10-222 A /31-1-
4- Rod - T40091/1-
5- Adapters - 10-222 A /31-4-
6- Adapters - 10-222 A /31-3-
– Take up weight of engine/gearbox assembly via the spindles.
– Remove the noise insulation located under the engine and

gearbox ⇒ Bodywork, exterior fitting work; Rep. gr. 50 .
– Pull connector -1- off reversing light switch - F4- .
– Remove retainer -2- from starter -arrow- and remove wiring
retainer from gearbox, if present.
– Removing the starter motor⇒ Electrical system; Rep. gr. 27 .

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– Remove cover plate -arrows-.
– Remove pendulum support -arrows A- and -B-.

– Separate the exhaust system from the subframe ⇒ Rep. gr.
26 .
– Remove coupling rod -1- from anti-roll bar on both sides ⇒
Running gear, axles, steering; Rep. gr. 40 .
– Press anti-roll bar upwards.
– Remove drive shaft heat shield, if present -arrows- ⇒ Running

gear, axles, steering; Rep. gr. 40 .
– Remove drive shafts from flange shafts of gearbox and tie up
as high as possible ⇒ Running gear, axles, steering; Rep. gr.
40 .

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– Check to see if a cover plate -A- is installed above the right

flange shaft.
– Remove cover plate -arrows-.
– Remove hexagon bolts -arrows- at left mounting from gearbox

mounting.
– Tilt engine and gearbox assembly by lowering spindles of sup‐
port bracket - 10-222 A- .
Note
When lowering engine and gearbox assembly, ensure that gear‐

box does not contact subframe in region of differential.
• Securing bolts -arrows- for gearbox bracket -A- must be ac‐

cessible. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove gearbox bracket -A- -arrows-.
– Assemble engine and gearbox support , gearbox support -
3282- , adjustment plate - 3282/31- for “02U” gearbox and
mounting elements as follows:
– Place adjustment plate - 3282/31- on gearbox support - 3282-
(adjustment plate only fits in one position).
– Align arms of gearbox support according to holes in adjust‐
ment plate.
– Screw in support elements -A- as illustrated on adjustment

plate.

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

adjustment plate points in direction of vehicle travel.
– Align adjustment plate parallel to gearbox and lock safety sup‐
port on gearbox.
– Remove engine/gearbox connecting bolt -arrow-.
– Remove engine/gearbox connecting bolt -A- in area of right

flange shaft.
Note
On some engines, the engine/gearbox connecting bolt is below

the right flange shaft.
– Push the gearbox off the dowel sleeves and swing carefully
towards the subframe.
– Carefully push the engine forwards with the assistance of an‐
other mechanic.
– When doing this, observe radiator.
– Turn gearbox downwards in vicinity of differential.
– Then carefully lower gearbox. When doing this, guide with

right-hand flange shaft -A- in area of flywheel and intermediate
plate as shown and with left-hand flange shaft -B- in area of
subframe.
– Press the wheel housing liner slightly to the left at the lower
side in order to ensure that it doe not make contact with the
gearbox.
– When lowering the gearbox, change position of gearbox using
the spindles on gearbox support - 3282- .
Note
Observe lower connection for coolant

Protected hose
by copyright. between
Copying for privateradiator and
or commercial purposes, in part or in whole, is not
engine. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
2.2 Installing gearbox

– Clean splines of input shaft and apply a thin coat of grease -
G000 100- .
The clutch plate should always be free to move from one side to
the other on the input shaft.
– Check if the centring sleeves are installed in the engine for the
purpose of centring the engine with the gearbox and insert
these if they are not installed.
– Ensure that intermediate plate is correctly seated on engine.
– Assemble engine and gearbox support , gearbox support -
3282- , adjustment plate - 3282/31- for “02U” gearbox and
mounting elements as follows:

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– Place adjustment plate - 3282/31- on gearbox support - 3282-

(adjustment plate only fits in one position).
– Align arms of gearbox support according to holes in adjust‐
ment plate.
– Bolt on support elements -A-, as illustrated on adjustment
plate.
– Align gearbox parallel to adjustment plate and set on engine
and gearbox jack .
– Lock safety support to gearbox.
– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
Note
When installing the gearbox, do not damage any cables or lines.
– Using spindles of gearbox support - 3282- , tilt gearbox down‐

wards in vicinity of differential.
other mechanic. When doing this, observe radiator.
– Then carefully raise gearbox. When doing this, guide with

right-hand flange shaft -A- in area of flywheel and intermediate
plate as shown and with left-hand flange shaft -B- in area of
subframe.
– Press the wheel housing liner slightly to the left at the lower
side in order to ensure that it doe not make contact with the
gearbox.
Note respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ Observe lower connection for coolant hose between radiator

and engine.
♦ Observe coolant hose between engine and heat exchanger for
heater.
– Attach gearbox.
– Screw in engine/gearbox connecting bolt -A- in area of right

flange shaft.
Note
On some engines, the engine/gearbox connecting bolt is below

the right flange shaft.
– After gearbox has been bolted to engine, remove engine and

gearbox jack from gearbox.
– Screw in the bolts at the bottom for the engine to the gearbox.

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– Fit gearbox bracket -A- with new bolts -arrows-.

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

box mounting.
WARNING
Do not remove support bracket - 10-222 A- until all bolts se‐

curing the assembly mounting have been tightened to speci‐
fied torque.
– Install upper engine/gearbox securing bolts.

– Use new bolts for securing pendulum support.
other mechanic.
– Install pendulum support -arrows A- and -B- ⇒ Rep. gr. 40 .
– Install cover plate -arrows-.

– Fit the complete half-shafts ⇒ Running gear, axles, steering;
Rep. gr. 40 .

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– Install the drive shaft heat shield, if present -arrows- ⇒ Run‐

ning gear, axles, steering; Rep. gr. 40 .
– On both sides, bolt coupling rod -1- onto anti-roll bar ⇒ Run‐
– Reassemble exhaust system ⇒ Rep. gr. 26 ; Exhaust system .
– Fit the starter motor ⇒ Electrical system; Rep. gr. 27 .
– If necessary, install earth strap on upper engine/gearbox con‐
necting bolt.
– Install bracket -2- on starter -arrow-.

– Push connector -1- onto reversing light switch - F4- .

– Plug on the connector -arrow- to the gearbox neutral position
sender - G701- .
Continuation for all vehicles Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Check for correct installation position of vacuum hose for
brake system, install vacuum hose if necessary ⇒ Rep. gr.
47 .

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– Install slave cylinder -C-.

– Press pipe/hose line -A- into retainer -B- on gearbox if neces‐
sary.
– Install cable support bracket on gearbox -arrows-.
– Install gearbox selector lever -B- and tighten hexagon nut

-arrow 2- to specified torque ⇒ Item 13 (page 61) .
– Install relay lever -A- together with cable end-piece
⇒ page 62 .
– Spread a small amount of grease on pin of gearbox selector
lever -B-.
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Connect gear selector cable to gearbox selector lever
-arrow 1-.
– Adjust selector mechanism ⇒ page 66 .
– Check gear oil ⇒ page 82 .
– Install the noise insulation located under the engine and gear‐
box ⇒ Bodywork, exterior fitting work; Rep. gr. 50 .
– Insert foam pieces or seal for plenum chamber cover into up‐
per edge of left and right wings ⇒ Body, front; Rep. gr. 50 .
– Fit the battery holder, the cover of the battery and the battery
itself ⇒ Electrical system; Rep. gr. 27 .
– Observe the procedures after connecting the battery ⇒ Elec‐
trical system; Rep. gr. 27 .
– Install air filter ⇒ Rep. gr. 24 .
Note
Note radio code for vehicles with coded radio.
2.3 Specified torques

Gearbox to engine
Item permitted Bolt Control
unless authorised by SEAT units
S.A. SEAT S.A does notNm
guarantee or accept any liability with
1 M12 x 60 3 80
2 M 12 x 135 / M 8 x 12 2 80
♦ Additionally, start‐
er to gearbox
3 M12 x 80 1 80
4 M10 x 25 2 40
Pos. -A- – Adjusting sleeves for centring

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Gearbox bracket -A- to gearbox

– Renew bolts -arrows-
– Pre-tighten all the bolts by hand.
– Tighten bolts to specified torque.
Bolts -arrows-: 40 Nm + 90°
Gearbox to bodywork
– Renew bolts
– Tighten all bolts hand-tight.
– Tighten bolts -arrows- to specified torque.
Bolts -arrows-: 40 Nm + 90°
Note
Install engine/gearbox mountings stress-free ⇒ Rep. gr. 10 ; Re‐

moving and installing engine .
Slave cylinder to gearbox ⇒ Item 12 (page 19) .

Gearbox selector lever to selector shaft ⇒ Item 13 (page 61)
Selector cable support bracket to gearbox ⇒ Item 9 (page 60) .
Pendulum support to subframe and gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40 .
Driveshaft to the flanged shaft ⇒ Running gear, shafts, steering;
Rep. gr. 40 .

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3 Checking gear oil

♦ Socket (27 mm) - 3257-
Gearbox oil ⇒ Electronic parts catalogue (ETKA)

– Unscrew the oil level test bolt for gears -arrow-.
Oil level is correct when gearbox is filled to lower edge of filler
hole.
– Tighten bolt -arrow- to specified torque ⇒ page 83 .
If the container must be completely filled with oil, note the follow‐
ing:
– Remove the bolt -arrow-.
– Fill with gear oil to lower edge of filler hole.
– Screw in plug -arrow-.
– Start the engine, shift into gear and let the transmission run for
about 2 minutes.
– Stop engine and remove plug -arrow-.
– Fill with gear oil to lower edge of filler hole.
– Tighten bolt -arrow- to specified torque ⇒ page 83 .

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Different versions of oil filler / oil drain plug

I - Oil filler or oil drain plug with multi-point socket head 25 Nm
II - Oil filler or oil drain plug with hexagon socket head 30 Nm
3. Checking gear oil 83

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4 Gearbox: disassembly and assembly

⇒ “4.1 General layout of gearbox”, page 84
⇒ “4.2 Assembly overview”, page 85
⇒ “4.3 Cover for gearbox casing and 5th/6th gear: removing and
installing – general overview”, page 86
⇒ “4.4 Assembly overview - removing and installing clutch hous‐
ing”, page 88
⇒ “4.5 Removing and installing input shaft, output shaft, differen‐
tial, selector mechanism and selector forks - Assembly overview”,
page 89
⇒ “4.6 Dismantling and assembling procedure”, page 90
4.1 General layout of gearbox
1 - gear
2 - 2. gear
3 - 3. gear
4 - 4. gear
5 - gear
6 - 6. gear permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
7 - Gearbox housing cover
8 - Gearbox
9 - Reverse gear pinion
10 - Gear selection mecha‐
nism
❑ (Selector forks)
11 - clutch housing
12 - Input shaft:
13 - Output shaft
14 - Differential

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4.2 Assembly overview

Dismantling and assembling procedure ⇒ page 90
I - Cover for gearbox casing

and 5th / 6th gear: removing
and installing ⇒ page 86
II - Removal and assembly of
clutch casing ⇒ page 88
III - Removal and assembly of
input shaft, layshaft, differen‐
tial, gear operation mechanism
and gear prongs ⇒ page 89
4. Gearbox: disassembly and assembly 85

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4.3 Cover for gearbox casing and 5th/6th gear: removing and installing – gen‐
eral overview
1 - Gearbox
❑ Repairing ⇒ page 106
2 - 5th gear pinion
⇒ page 102
❑ It must be pressed in
and out ⇒ page 128
with several gearboxes
⇒ page 102 .
3 - Drift sleeve
4 - Gear wheel for 6th gear
⇒ page 103
5 - Internal ring of the spherical
roller bearing
❑ From the secondary
shaft.
❑ Apply marking prior to
removal
❑ Do not confuse with the
inner ring of the input
shaft roller bearing
socket
6 - Bolt
❑ M8: 30 Nm then turn 90°
further
❑ M10: 75 Nm then turn
45° further
❑ For secondary shaft
❑ Self-locking
❑ Always replace
❑ With roller bearings for input and output shafts
8 - Bolt, 5 Nm + turn 90° further
❑ Always replace
9 - Plug
❑ M8: 30 Nm then turn 90° further
❑ M10: 75 Nm and turn 45° further
❑ For input shaft
❑ Self-locking
❑ Always replace
10 - Internal ring ofrespect
the spherical roller
to the correctness bearingin with
of information thrustCopyright
this document. washer by SEAT S.A.
❑ For input shaft

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11 - 6th speed selector gear

12 - Synchro-ring for 6th gear
13 - Two-piece needle bearing
❑ For 6th gear
❑ This is a single-part version with several gearboxes.
❑ Allocate according to ⇒ Electronic parts catalogue “ETKA”
❑ Replace together with sleeve.
14 - Drift sleeve
❑ For 6th gear needle bearing.
❑ Renew together with needle bearing.
15 - Locking collar with synchronising hub for 5th and 6th gear
❑ Dismantling and assembling ⇒ page 122 .
16 - 5th / 6th gear selector fork
17 - Pivot pin
❑ For 5th gear selector fork.
18 - Synchromesh ring of 5th gear:
❑ This will be damaged when the input shaft is removed
❑ Always replace
19 - Mobile pinion of 5th gear
20 - Needle bearing
❑ for 5th gear

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4.4 Assembly overview - removing and installing clutch housing
1 - Countersunk bolt
2 - Flange shaft with compres‐
sion spring
⇒ page 90
❑ Assembling
⇒ page 148
❑ Always replace
4 - clutch housing
5 - Gearbox
6 - Clutch release lever:
❑ With guide sleeve and
release bearing
⇒ page 90
7 - Bolt

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4.5 Removing and installing input shaft, output shaft, differential, selector mech‐
anism and selector forks - Assembly overview
1 - Differential
❑ Dismantling and assem‐
bling ⇒ page 150 .
2 - Gearbox
3 - Oil drain plug, torque setting
⇒ page 83
4 - Flange shaft with compres‐
sion spring
⇒ page 90
❑ Assembling
⇒ page 148
5 - Countersunk bolt
❑ Self-locking
❑ Always replace
❑ To secure bearing
mounting with deep
groove ball bearing for
input and output shafts
⇒ Item 18 (page 90) .
7 - Hexagon flange nut, 23 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For selector mechanism respect to the correctness of information in this document. Copyright by SEAT S.A.
⇒ Item 17 (page 90) .
❑ Self-locking
❑ Always replace
8 - O-ring
❑ Always replace
9 - Pivot pin
❑ Always replace
11 - Selector shaft with selector shaft cover
❑ (Control unit)
❑ Always replace
13 - Bolt, 6 Nm
14 - Gearbox neutral position sender - G701-
❑ For vehicles with start stop system
15 - Reversing light switch - F4- , 20 Nm
❑ With captive seal (fitted shortly after gearbox was first introduced)
16 - Seal
❑ Not fitted on all gearboxes

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17 - Gear selection mechanism

❑ (Selector forks)
❑ Dismantling and assembling ⇒ page 117 .
18 - Input shaft and output shaft with bearing mounting and deep groove ball bearing
❑ Replace the allotment whenever it detaches from the gearbox casing
❑ Pressing bearing mounting off and on ⇒ Item 13 (page 123) .
❑ Disassembly and assembly of the input shaft ⇒ page 122
❑ Disassembly and assembly of the secondary shaft ⇒ page 133
19 - Reverse gear pinion axis
20 - Reverse gear pinion
21 - Plug
❑ For reverse gear shaft
❑ Always replace
4.6 Dismantling and assembling procedure

⇒ “4.6.1 Modifying gearbox support 3221 ”, page 94
⇒ “4.6.2 Dismantling”, page 94
⇒ “4.6.3 Assembling”, page 99
Removing and installing gearbox housing cover, clutch housing,
selector shaft with selector mechanism cover, input shaft, output
shaft, differential and selector mechanism.

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equipment required
♦ Support equipment -
VW 313-
♦ Pressure plate - VW 401-
♦ Press die - VW 412-
♦ Gearbox holder - 3221A-
♦ or gearbox support - 3221-
(modifying ⇒ page 94 )
♦ Guide pin - T10079-

Toledo 2013 ➤

♦ Tube element - VW 418 A-
♦ Thrust pad - 3074-
♦ Thrust pad - T10080-
♦ Base for fitting - T10083-
♦ Washer - T10083/1-
♦ Tray - V.A.G 1306-

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V.A.G 1331-
♦ -2- Divider - Kukko 18/1-
♦ -3- Splitter - Kukko 17/1-
♦ -1- Three arm puller - Kuk‐
ko 30/1-
♦ -3- Two-arm puller - Kukko
204/2-
♦ Hexagon socket head bolts
M8 x 15
♦ Extractor - T10309-
♦ Half sleeve - T10309/4-
♦ Adapters - T10309/5-
♦ Sealing paste - AMV 188
200 03-

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4.6.1 Modifying gearbox support - 3221-

If you are using gearbox support - 3221- :
To secure gearbox 02T on gearbox support - 3221- , a new hole
is required.
Dimensions are given in mm.
– Drill an 11.0 mm ∅ hole -arrow- in gearbox support - 3221- .
4.6.2 Dismantling
– Secure on gearbox support - 3221- or on gearbox support -
3221A- -arrows-.
– Place below the collecting tray - V.A.G 1306- .
– Drain gear oil.
– Remove clutch release lever -A- with clutch release collar and
guide sleeve -arrows-.
– Remove bolt securing right flanged shaft -B-. Screw 2 bolts
into flange and counterhold flange shaft using a lever.
– Remove the flanged shaft with the compression spring, thrust
washer and conical ring.
– Unscrew the gearbox casing cover -arrow- and remove with

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

Toledo 2013 ➤
– Pull out pivot pin -1- for 5th and 6th gear selector fork -2- and
remove selector fork.
– Remove bolts -A- for the inner rings of the input shaft and lay‐
shaft bearings. For this purpose, 5th gear -arrow 1- and 1st
gear must be engaged (-arrows 2- and -3-).
– After engaging both gears, the input shaft and the layshaft are
locked. Now the two bolts can be loosened.
Note
♦ If the shafts are not being renewed, clean residual locking

compound out of tapped holes using a thread tap.
♦ Pull off gear wheel for 6th gear with three arm puller - Kukko
30/1- .
♦ If necessary, gear wheel for Protected
6th gear can beCopying
by copyright. pulled
for off toorstop
private commercial purposes, in part or in whole, is not
on spindle with two arm puller - Kukko
permitted 204/2-by. SEAT
unless authorised Then S.A.pull
SEAToff
S.A does not guarantee or accept any liability with
further with three arm puller - Kukko 30/1-
respect to .
the correctness of information in this document. Copyright by SEAT S.A.
– Pull off 6th gear wheel and roller bearing inner race for output
shaft.
A - Three-arm puller - Kukko 30/1-
B - Hexagon socket head bolt - M8 x 15-
Remove synchromeshed gear for 6th gear along with synchro-
hub for 5th and 6th gear, the inner race for needle bearing for 6th
gear, and the synchro-ring for 5th gear.
Use puller - T10309- .

Toledo 2013 ➤
– First insert half sleeve - T10309/4- .

• Half sleeve - T10309/4- must be positioned beneath synchro-
ring.
– If necessary, half sleeve must be pressed to end position.
– Position adapter - T10309/5- .
– Place the thread insert - T10309/3- into the half shell and lightly
brace.
– Install second half sleeve - T10309/4- now and fit tube -

T10309/2- onto assembly.
Note
Once it has been removed, the synchromesh ring for 5th gear
must always be renewed. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Extract the bolt fastening the flanged shaft. To do so, thread
2 bolts on the flange and lock the shaft using the assembly
lever.

Toledo 2013 ➤
– Remove flanged shaft -1- together with compression spring.

– Remove sleeve -2- and 5th gear synchromeshed gear with
needle bearing -4-.
– Unscrew the hexagonal nut with the collar -5- from the gear
operation mechanism (to secure the reverse gear).
– Unscrew the bolts -6- securing the input shaft and secondary
shaft bearing allotment.
The 5th gear sprocket can be removed by hand.
– Remove gear wheel for 5th gear -3-.
The 5th gear sprocket cannot be removed by hand.
– The gear wheel for 5th gear -3- will be pressed off later when
the bearing support for the deep groove ball bearing
⇒ page 128 .
– Turn gearbox in support bracket so that clutch housing is up‐
wards.
– Unscrew the bolts securing the gearbox housing to the clutch
housing.
– Separate the clutch housing by levering carefully on the rein‐
forced tabs of the housing, on each side, and avoiding damage
to the sealing surfaces.
– Do not tilt the clutch housing to prevent damage to the roller
bearings or their seating in the input and lay shafts.
– Remove the differential -A- from the gearbox casing.

– Remove the gearbox neutral position sender - G701-
-arrow-.

Toledo 2013 ➤
– Remove selector shaft with selector cover -A-. Place selector

shaft in neutral. Then remove the bolts -arrows- and take the
selector shaft out of the gearbox casing.
– Take the bearing bush pins -B- out of the upper part of the
gearbox.
– Unscrew the reverse light switch - F4- -C-.
– Unscrew the bolt -A- for securing the reverse gear pinion shaft
– Take the bearing bush pins -B- out of the lower part of the
gearbox.
Note
Do not remove the cover -arrows- to remove the gearbox.
The 5th gear sprocket could not be removed.
– Press out input shaft, output shaft with gear wheel for 5th gear
-A-, bearing mounting, selector mechanism (selector forks)
and reverse gear together.
Note
♦ Place the gearbox casing to ensure the adjustment bearings

are not damaged.
♦ When releasing the components, ensure they do not fall on
the ground (if necessary, ask for the help of a second me‐
chanic).
The 5th gear sprocket could be removed.
– Detach the input and lay shafts with the allotment, the gear
operation mechanism (prongs) and the reverse gear.
Note
♦ Place the gearbox casing topermitted

ensure the adjustment bearings
are not damaged.

♦ When releasing the components, ensure they do not fall on

the ground (if necessary, ask for the help of a second me‐
chanic).

– Press out the drive shaft and drive shaft together with the 5th
gear sprocket with grooved ball bearing from the bearing
mount ⇒ page 128 .
– Press out the drive shaft and drive shaft together without the
5th gear sprocket with grooved ball bearing from the bearing
mount ⇒ page 128 .

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4.6.3 Assembling
Note
♦ Insert the allotment with grooved ball bearings for the input
and secondary shafts ⇒ page 132 .
♦ Pressing sleeve for 5th speed selector gear needle roller bear‐
ing onto input shaft ⇒ page 132 .
5th gear sprocket is located in the drive shaft

– Position assembled components, input shaft -2- and output
shaft -1- with bearing mounting for deep groove ball bearing,
in thrust piece - T10080- .
– Insert the gear operation mechanism (prongs) -4- on the mo‐
bile sleeves of the shafts.
– Fit the reverse gear shaft -3- with the pinion.
– Screw in the guide sleeve - T10079- on the reverse gear
threaded attachment pin -arrow-.
5th gear sprocket is not located in the drive shaft
– Position assembled components, input shaft -2- and output

shaft -1- with bearing mounting for deep groove ball bearing,
in thrust piece - T10080- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Insert the gear operation mechanism (prongs)
respect to the -4- on the
correctness mo‐
of information in this document. Copyright by SEAT S.A.
bile sleeves of the shafts.
– Fit the reverse gear shaft -3- with the pinion.
– Screw in the guide sleeve - T10079- on the reverse gear
threaded attachment pin -arrow-.

Toledo 2013 ➤

– Insert components together in gearbox housing. To do this,
guide guide pin - T10079- through hole for attachment of se‐
lector mechanism in gearbox housing.
– Unscrew guide pin - T10079- .
Before adapting, the following must be checked.
♦ The selector forks must engage in the locking collar correctly.

♦ The spacing -a- on the splines of output shaft.
Note
♦ The input shafts of the different gearboxes have different

lengths as dimension -a- of the splines do not correspond.
♦ In order to allow an equal fit between the secondary and input
shafts, a washer - T10083/1- (3 mm thick) has to be mounted
on the input shaft.
♦ For this person, permitted
dimension -a- of the secondary shaft
does splines
unless authorised by SEAT S.A. SEAT S.A not guarantee or accept any liability with
has to be measured. respect to the correctness of information in this document. Copyright by SEAT S.A.
Dimension -a- = 30.6 mm

Place the washer - T10083/1- on the output shaft ⇒ page 100
Place the washer - T10083/1- onto the output shaft and – carefully
– press in the allotment together with the input and output shafts
to the end.

Toledo 2013 ➤
Carefully insert the allotment together with the input and secon‐
dary shafts to the end.
– Screw in the bolt -A- for securing the reverse gear pinion shaft.
– Fit the bearing bush pins -B- in the lower part of the gearbox.
– Screw the reverse light switch - F4- -C-.

– Fit the bearing bush pins -B- in the upper part of the gearbox.
– Place the gearshift lever in neutral position.
– Apply sealing paste - AMV 188 200 03- uniformly on the seal‐
ing surface of the selector shaft cover.
– Install selector shaft with selector cover -A-. Then tighten bolts
-arrows-.

– Mount the gearbox neutral position sender - G701- -arrow- and
tighten the screw with the respective tightening torque
⇒ Item 13 (page 89) .

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– Tighten the input shaft and secondary shaft allotment with new
bolts -A-.
Note
Tighten the bolts in stages to the specified torque in diagonal se‐

quence, starting in the centre.
– Tighten hexagon flange nut -B- for selector mechanism (se‐

lector forks).
– Place the input and lay shafts together with the gearbox casing
in the base for fitting - T10083- .
Installation position of 5th gear wheel

The highest collar -arrow- should be orientated towards the gear‐
box casing.
Install gear wheel for 5th gear -1- and sleeve -2- as long as they
have been removed by hand.
Insert the 5th gear pinion if it has been removed.

– Mount the sleeve for 5th gear sprocket ⇒ Figure top, Pos.
-2-.
– Install 5th speed selector gear with the 5th gear synchroniser
ring and the needle bearing ⇒ page 103 item -1-.
Installation position of 5th/6th gear synchronising hub/locking col‐

lar
The highest collar -arrow- must face towards 5th gear and the
gearbox casing.

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Detach 5th gear selector gear (Pos. -1-) with synchro-ring and
mount the needle bearing.; press-on the synchroniser ring and
5th / 6th gear sliding sleeve.
WARNING
Wear protective gloves!
– Heat the inner ring of the needle bearing of 6th gear to a max‐
imum of 100°C and fit.
– Put on synchro-ring for 6th gear.
– Fit 6th gear selector gear with the needle bearing.
– Heat roller bearing inner race -A- to 100°C (maximum) and

drive onto output shaft.
WARNING
Installation position of 6th gear wheel:

High inside collar faces 5th gear sprocket.
– Move locking collar for 5th and 6th gear -A- to idle. In this way,
the 6th gear mobile pinion mobile pinion can rotate and the
sprocket of this gear can be adapted.
WARNING
– Heat gear wheel for 6th gear to maximum 100° C.

– Press on gear wheel for 6th gear, being careful that teeth of
gear wheel -B- and synchronised gear for 6th gear -C- mesh.

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– Heat the roller bearing inner ring -A- to approx. 100 ºC, and fit
it onto the lay shaft.
– Install differential -A-.

– Apply an even coat of sealant paste - AMV 188 200 03- on the
sealing surface.
– Secure clutch housing to gearbox housing.
– Turn gearbox in support bracket so that gearbox housing is
upwards.
– Turn gearbox
Protected in supportCopying
by copyright. bracket so that
for private gearbox
or commercial housing
purposes, isin whole, is not
in part or
upwards.
– Before tightening the fastening bolts -A- 2 gears should be

engaged (-arrows 1- and -3-).

Toledo 2013 ➤
– Insert the 5th / 6th gear selector fork -2- and slide the pivot pin
-1- in onto stop in direction of -arrow-.
– Apply an even coat of sealant paste - AMV 188 200 03- on the
sealing surface.
– Tighten screws to secure the gearbox casing cover.
– Install both flange shafts with springs, thrust washers and ta‐
pered rings.
– Install clutch release lever together with the clutch release col‐
lar and guide sleeve ⇒ page 50 .

Toledo 2013 ➤
5 Gearbox casing and clutch housing: repairs

equipment required
♦ Press die - VW 408 A-
♦ or drift - 2026-
♦ Spacer bush - VW 472/2-
♦ Centring mandrel. - 12 -
551-
♦ Thrust pad - 30 - 555-
♦ Spindle from assembly tool
- 3066-

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♦ Gearbox support - 3221-

(modifying ⇒ page 94 )
♦ Multi-point bit - 3357-
♦ Thrust piece - T40008-
V.A.G 1331-
♦ -2- Divider - Kukko 18/1-
♦ -3- Splitter - Kukko 17/1-
5. Gearbox casing and clutch housing: repairs 107

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1 - clutch housing
❑ If replaced, adjust the
differential ⇒ page 156
2 - Join ring for the input shaft
❑ Remove levering with a
screwdriver
3 - Spherical head pin
4 - Left flanged shaft seal:
❑ replace with gearbox in‐
stalled ⇒ page 145
5 - Drift sleeve
❑ For oil seal.
❑ Remove ⇒ page 109
6 - Oil filler plug, torque setting
⇒ page 83
7 - O-ring
❑ If fitted, always renew
8 - Sealing cap
❑ Always replace
10 - Shim
❑ For the differential
❑ Determining thickness
⇒ page 156
11 - Outer track, roller bearing
❑ Pulling out and pressing in ⇒ page 148
❑ If replaced, adjust the differential ⇒ page 156
12 - Bolt, 5 Nm and tighten 90 º more
❑ Always replace
❑ For the differential permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Pulling out and pressing in ⇒ page 150


14 - Adjustment bush
❑ 2 off
15 - Gearbox
16 - Oil drain plug, torque setting ⇒ page 83
❑ replace with gearbox installed ⇒ page 143
18 - Drift sleeve
❑ For selector shaft
❑ Pressing out ⇒ page 110

Toledo 2013 ➤

19 - Electromagnet
❑ Supported by the application surface of the housing
20 - End cover
❑ Apply an even coat of sealant paste - AMV 188 200 03- on the sealing surface, before bolting down.
21 - Securing ring
❑ Insert in groove of cylindrical roller bearing ⇒ Item 24 (page 109) .
22 - Circlip
❑ Insert in groove of cylindrical roller bearing ⇒ Item 23 (page 109) .
23 - Cylindrical roller bearing
❑ For input shaft
Protected ⇒ page
by copyright. 122 for private or commercial purposes, in part or in whole, is not
Copying
24 - Cylindrical roller respect
bearingto the correctness of information in this document. Copyright by SEAT S.A.
❑ From the secondary shaft.

Driving in input shaft oil seal flush
Pulling out oil seal sleeve

– Fit spacer sleeve - VW 472/2- and press tool - 30 - 555- onto
differential.
A - Puller , e.g. -Kukko 18/1-
B - Splitter 12...75 mm , e.g. -Kukko 17/1-
5. Gearbox casing and clutch housing: repairs 109

Toledo 2013 ➤
Drawing in oil seal sleeve

A - Screw spindle from assembly device - 3066- into threaded
piece of differential.
B - M12 nut with washer
– Turn nut -B- and pull sleeve in onto stop with thrust piece -
3124- .
Note
If gearbox has been dismantled, press in sleeve onto stop using

thrust piece - 3124- .
Remove the selector shaft bush -A-
Driving in selector shaft sleeve -A-

The sleeve -A- for the selector shaft can also be driven in with the
drift - 2026- .

Toledo 2013 ➤
6 Gearbox casing cover: repairing

equipment required
♦ Inlay socket - 40 - 21-
♦ Support bridge - 2011-
♦ -1- Interior extractor - Kuk‐
ko 21/6-
♦ -4- Support bracket - Kukko
22/2-
V.A.G 1783-
6. Gearbox casing cover: repairing 111

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1 - Countersunk screw, 2 Nm
❑ Tighten diagonally and
alternately
2 - Retaining plate
❑ For cylindrical roller
bearing
❑ Installation position: de‐
pression for the screws
must point to the gear
housing.
❑ For input shaft
roller bearing socket for
the secondary shaft
❑ From the secondary
shaft.
roller bearing socket for
the input shaft
Release the roller bearing socket from the gearbox casing cover
A - Internal puller 37...46 mm , e.g. -Kukko 21/6-
B - Counter-support , e.g. -Kukko 22/2-

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Insert the roller bearing socket on the gearbox casing cover

– Heat the cover of the gearbox casing to about 100°C and eat
the seating surface of the bearing using a hot air blower, e.g.
-V.A.G 1416- .
– Place the roller bearings in the previously heated casing and
press with the workshop press until the heat is transferred.
Note
The roller bearings must be fitted in the cover as far as possible.

Do not tighten with the countersunk bolts through the support
plate.
6. Gearbox casing cover: repairing 113

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7 Gear mechanism: repairing

♦ Tube element - T10203-
♦ Tube element - VW 423-

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1 - Drift sleeve
❑ For selector shaft
❑ Pressing out
⇒ page 110
2 - Selector shaft with selector
shaft cover
❑ Renew together
3 - Angled rod
❑ To adjust the gear se‐
lection mechanism
4 - Return lever
❑ Installing
5 - Wiring clip
6 - Seal
❑ Lever out with a screw‐
driver
7 - Cap
❑ For gearbox breather
8 - Gear lever
❑ Installing
9 - Hexagonal nut
❑ ⇒ Item 13 (page 61)
Removing angled rod -A- from selector shaft cover

– Remove outer part of angled rod.
– Then carefully lever out angled rod using a screwdriver.

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Pressing angled rod -A- into selector shaft cover

Installation position:
Mark -1- should be facing mark -2- on the selector shaft cover.
Insert the seal -A- as far as possible.

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8 Dismantling and assembling selector forks

equipment required
♦ Thrust pad - 3290/1-
♦ Assembly tool - 3301-
♦ Thrust pad - VW 431-
♦ Die - 10 - 206-
♦ Release lever - 80–200-
8. Dismantling and assembling selector forks 117

Toledo 2013 ➤
♦ Drift - 10 - 508-
♦ attachment tool - 2070-
Note
It is not necessary to dismantle the gearbox prong unit ⇒ Item 1 (page 119) to remove and assemble the
gearbox selector rods, the fastening washers and the ball bearings.

Toledo 2013 ➤
1 - Gearbox prong unit with

strips
2 - Selector segment for 3rd
and 4th gear
❑ After assembly, it
should still be possible
to turn slightly
❑ Identification
⇒ page 120
3 - Angular contact ball bearing
❑ 4 off
❑ Pressing inner race into
outer race ⇒ page 121
4 - Securing washer
❑ Always replace
5 - 1st/2nd gear selector seg‐
ment
❑ Identification
⇒ page 120
❑ The gear selection
group should still be free
to rotate slightly after fit‐
ting the fastening ring
❑ Selector fork with selec‐
tor segment
⇒ page 120
6 - ProngsProtected
of 5th/6th gearCopying
by copyright. with for private or commercial purposes, in part or in whole, is not
gear selection.
❑ The gear selection can
not be separated from the prong
❑ Identification ⇒ page 120
7 - Pivot pin
❑ For the 5th/6th gear prong

Toledo 2013 ➤
Identification of selector segments and selector fork for 5th and

6th gear with selector segments
Gap -a-
1- 1st/2nd gear selection group = 10.0 mm
2- 3rd/4th gear selection group = 78.6 mm
3- Prongs of 5th/6th gear with gear selection = 79.5 mm.
Selector fork for 1st and 2nd gears with selector segments
Dimension -a- = 78 mm
Removing lock washer

– Fasten the prong to a workshop vice with clamps -B-.
– Remove the washer -A- by levering in the direction of the ar‐
row. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installing lock washer

– Press lock washer into groove of selector segment using sock‐
et and spinner handle.
Note
The gear selection group should still be free to rotate slightly after
fitting the fastening ring
A - Spinner handle with 10 mm socket

B - Protective jaw covers

Toledo 2013 ➤
Remove ball bearings
Note
Do not bend the prongs when removing and fitting the ball bear‐
ings.
Pressing inner race -A- of angular contact ball bearing into outer
race
The inner ring should fit in the outer ring.
Fit the ball bearings as far as possible in the gearbox prong

Depression in thrust piece - 3290/1- faces ball bearing.

Toledo 2013 ➤
35 – Gears, shafts
1 Input shaft:
⇒ “1.1 Input shaft: assembly overview”, page 122
⇒ “1.2 Disassembly and assembly of the input shaft”, page 125
1.1 Input shaft: assembly overview

Dismantling and assembling input shaft ⇒ page 125 .
Note
♦ When installing new gears or a new input shaft, all details of the ⇒ Electronic parts catalogue “ETKA” and
technical data must be observed.
♦ Install all bearings, synchromeshed gears and synchro-rings on input shaft with gear oil.
♦ Do not mix up synchromesh rings. If re-using, allocate them to corresponding mobile pinion.
1 - Bolt
⇒ page 86
2 - Internal ring of the spherical
roller bearing with thrust wash‐
er
⇒ page 90
3 - 6th speed selector gear
❑ Check for wear
⇒ page 129
5 - Needle bearing
❑ For 6th gear
❑ This is a two-part ver‐
sion with several gear‐
boxes.
❑ Replace
Protectedalong withCopying for private or commercial purposes, in part or in whole, is not
by copyright.
⇒ permitted
Itemrespect
10 (page 123)
6 - Drift sleeve
❑ For 6th gear needle
bearing.
❑ Replace together with
Item
⇒ page 90
7 - Locking collar with synchro‐
nising hub for 5th and 6th gear
⇒ page 90
❑ Dismantling
⇒ page 132
❑ Assembling 5th/6th gear locking collar/synchronising hub ⇒ page 132 ⇒ page 132
122 Rep. gr.35 - Gears, shafts

Toledo 2013 ➤
8 - Synchromesh ring of 5th gear:

❑ This will be damaged when the input shaft is removed
❑ Always replace
❑ Check for wear ⇒ page 129
10 - Needle bearing
❑ for 5th gear
❑ Replace along with ⇒ Item 11 (page 123)
11 - Drift sleeve
❑ For 5th gear needle bearing
❑ Press off with bearing mounting with deep groove ball bearing ⇒ page 128
12 - Gearbox permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
13 - Bearing mounting with grooved ball bearing
❑ Always replace the grooved ball bearings with the allotment
❑ Press off without gear wheel for 5th gear ⇒ page 128
❑ Press off with gear wheel for 5th gear ⇒ page 128 ⇒ page 128
14 - Input shaft:
❑ Clean any traces of fixing agent from the threaded holes in the input shaft using a tap.
15 - Needle bearing
❑ for 3rd gear
16 - 3rd speed selector gear
17 - Synchromesh ring of 3rd gear
18 - Locking collar with synchro-hub for 3rd and 4th gears
❑ Press off with 3rd gear synchromeshed gear ⇒ page 128
❑ Dismantling ⇒ page 129
❑ Installation position, locking collar and synchro-hub ⇒ page 129
❑ Assembling ⇒ page 129
19 - Drift sleeve
❑ For needle bearing for the 4th gear
❑ Replace together with Item ⇒ Item 20 (page 123)
❑ Press off with 3rd gear synchromeshed gear ⇒ page 128
20 - Needle bearing
❑ for 4th gear
1. Input shaft: 123

Toledo 2013 ➤

23 - Thrust washer
24 - Internal ring of the spherical roller bearing
25 - Securing ring
❑ Renew
❑ Determining thickness ⇒ page 131
❑ With retaining ring
❑ Installation position: the securing ring of the bearing must point to the input shaft
27 - clutch housing
28 - Spring
29 - Locking collar for 3rd and 4th gear
30 - Synchromesh body of 3rd and 4th gear
31 - Locking pieces (3 off)
32 - Spring
34 - Synchronising hub for 5th and 6th gear
35 - Locking collar for 5th and 6th gear

Toledo 2013 ➤
1.2 Disassembly and assembly of the input shaft

equipment required
1. Input shaft: 125

Toledo 2013 ➤

♦ Locking plate - 30 - 23-
♦ Press tool - 30 - 100-
♦ Thrust piece - T10080-

Toledo 2013 ➤
♦ Base for fitting - T10083-

♦ Pressure plate - T10084 A-
♦ -1- Interior extractor - Kuk‐
ko 21/5-
♦ -4- Support bracket - Kukko
22/1-
Dismantling input shaft.

Extract the roller bearing from the clutch housing
– On removing the roller bearing, press the safety ring -arrow-
with pliers -C-.
A - Counter-support , e.g. -Kukko 22/1-
B - Internal puller 30...37 mm , e.g. -Kukko 21/5-
1. Input shaft: 127

Toledo 2013 ➤
Pressing cylindrical roller bearing into clutch housing

– Support clutch housing using tube - VW 415 A- (not visible in
diagram) directly under bearing mounting.
– On fitting the roller bearing, press the safety ring -arrow- with
pliers -A-.
– Remove pliers before cylindrical roller bearing is in installation
position. Retaining ring must engage in groove of clutch hous‐
ing.
If the 5th gear sprocket -A- cannot be removed by hand.
Pressing off bearing mounting with deep groove ball bearing and
gear wheel for 5th gear -A-
– Slide locking collar for 1st and 2nd gear onto 2nd gear.
– Slide in thrust plate - T10084 A- sideways until it contacts input
shaft.
If the 5th gear sprocket can be removed by hand.
Detach the allotment with grooved ball bearings

shaft.
– Remove the securing ring.
Release theauthorised
permitted unless inner ring of S.A.
by SEAT theSEAT
roller
S.A bearing
does not guarantee or accept any liability with
– Remove the inner race of roller bearing together with the fol‐
lowing components:
♦ thrust washer,
♦ 4th speed selector gear with needle bearing
♦ Locking collar assembly unit with synchro-hub for 3rd and 4th
gears and
♦ Mobile pinion of 3rd gear.
Dismantling and assembling 3rd and 4th gear locking collar and
synchronising hub ⇒ page 129 .
Assembling input shaft.

Toledo 2013 ➤
Dismantling and assembling 3rd and 4th gear locking collar and
synchro-hub
1- Spring
2- Mobile element
3- Synchro-hub
4- Locking piece
– Slide locking collar over synchro-hub.
Deeper notches -arrow A- for locking pieces in synchro-hub and
notches -arrow B- in locking collar must align.
Assemble the mobile sleeve and synchromesh unit
respectfor 3rd
to the and of information in this document. Copyright by SEAT S.A.
correctness
4th gear
• The mobile element is on the synchromesh body.
– Fit the locking elements in the deepest grooves -arrows- and
fit the elastic rings off-set by 120º. Angled end of spring must
locate in hollow locking piece.
Installation position of locking collar with synchro-hub for 3rd and

4th gears
The groove on the front -arrow- should face towards 4th gear.
Check the wear of the synchromesh ring

– Press synchro-ring onto cone of synchromeshed gear and
measure gap “a” using feeler gauge.
Gap -a- Installation dimen‐ Wear limit
sion
3., 4., 5. and 6th 1.1 … 1.7 mm 0.5 mm
gear
– Install synchromeshed gear for 3rd gear with needle bearing
and synchro-ring.
1. Input shaft: 129

Toledo 2013 ➤
Pressing on synchro-hub with locking collar for 3rd and 4th gears
Installation position: The high collar faces 3rd gear wheel.
Pressing on sleeve -A- for 4th gear needle bearing

– Fit the needle bearing for 4th gear with mobile pinion and the
thrust washer. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Insert the inner ring -A- of the cylindrical roller bearing.

Toledo 2013 ➤
Determining thickness of circlip

– Insert a 2.0 mm strong circlip -A- in groove of input shaft and
press upwards -arrow-.
– Measure the distance between the inner ring -B- and the se‐
curing ring fitted -A- using a thickness gauge -C- .
– Remove the securing ring used for the measurement.
– Identify the correct securing ring using the table.
Note
See ⇒ Electronic catalogue of spare parts “ETKA” to allocate

securing rings.
The following retaining rings are available:

Measured value Retaining ring thick‐ Axial play (mm)
(mm) ness (mm)
0.05 … 0.14 2.0 0.05 … 0.15
0.15 … 0.24 2.1 0.05 … 0.15
0.25 … 0.34 2.2 0.05 … 0.15
0.35 … 0.44 2.3 0.05 … 0.15
0.45 … 0.51 2.4 0.05 … 0.10
Press bearing mounting with deep groove ball bearing onto input
shaft and output shaft.
Note
♦ The input shafts of the different gearboxes have different

lengths as the dimension of the splines - dimension -a- - does
not always correspond (the figure shows the shaft mounted).
♦ In order to ensure for an equal fit of the allotment on the shaft,
the shaft must always be inserted equally into the thrust piece
- T10083- .
♦ If necessary, insert a shim - T10083/1- (3 mm thick) into fitting
hole for input shaft ⇒ page 131by. copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
♦ For this person, dimension -a- of the secondary shaft splines
has to be measured.
Dimension -a- = 30.6 mm

Insert a washer - T10083/1- ⇒ page 131
Fit shim - T10083/1- .
1. Input shaft: 131

Toledo 2013 ➤
Adapt the bearing mount

– Before fitting, heat the allotment to a max. of 100 °C.
WARNING
Pressing on sleeve -A- for 5th gear needle bearing
Dismount and assemble mobile element and synchromesh body

of 5th / 6th gear
1- Spring
2- Locking piece
3- Installation position of synchronising hub: The groove on the
front part -arrow A- and the widest collar -arrow B- should
point towards 5th gear.
4- Mobile element
Deeper notches -arrow C- for locking pieces in synchro-hub and
notches -arrow D- in locking collar must align.
Insert the unit comprising locking collar and synchromesh body

of 5th / 6th gear.
fit the elastic rings off-set by 120º.
• Angled end of spring must locate in hollow locking piece.

Toledo 2013 ➤
2 Output shaft
⇒ “2.1 Output shaft: Installation overview”, page 133
⇒ “2.2 Input shaft: disassembly and assembly”, page 136
2.1 Output shaft: Installation overview

Disassembly and assembly of the secondary shaft ⇒ page 136 .
Note
♦ When installing new gears or a secondary input shaft, all details of the ⇒ Electronic parts catalogue “ETKA”
and technical data must be observed.
♦ Install all bearings, synchromeshed gears and synchro-rings on output shaft with gear oil.
♦ Do not mix up synchromesh rings. If re-using, allocate them to corresponding mobile pinion.
1 - clutch housing
❑ With retaining ring
❑ Installation position: re‐
taining ring in bearing
faces output shaft
3 - Output shaft
❑ For a cylinder roller
bearing (item
⇒ Item 2 (page 133) )
with seat on an inner
ring, the bearing can not
be removed from the
secondary shaft Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Check the seating or the respect to the correctness of information in this document. Copyright by SEAT S.A.
inner cylindrical bearing
ring for damage or scor‐
ing
❑ If the seating or the inner
cylindrical bearing ring
shows scoring or dam‐
age then replace the
secondary shaft and the
cylindrical roller bearing
❑ Fitting location: Collar
faces 3rd gear
⇒ page 139
5 - Circlip
6 - Circlip
7 - 3rd gear wheel
❑ Fitting location: Collar faces 4th gear ⇒ page 139
2. Output shaft 133

Toledo 2013 ➤
8 - Circlip
9 - Synchromeshed gear for 2nd gear
10 - Needle bearing
❑ For 2nd gear
11 - Inner ring for 2nd gear bearing
12 - Outer ring for 2nd gear
❑ Place above inner ring ⇒ Item 11 (page 134)
❑ Replace if there are signs of scoring and wear
13 - 2nd gear synchroniser ring
14 - Locking collar with synchronising hub for 1st and 2nd gear
❑ After removing retaining ring ⇒ page 138 , press off with 2nd gear synchromeshed gear
❑ Dismantling ⇒ page 140
❑ Assembling locking collar/synchronising hub ⇒ page 140 and ⇒ page 140
15 - Securing ring
❑ Fitting ⇒ page 141
16 - Synchro-ring for 1st gear
❑ Fit so that the grooves insert in the locking elements of the mobile sleeve ⇒ Item 14 (page 134)
17 - Outer ring for 1st gear
❑ Insert in synchro-ring ⇒ Item 16 (page 134) . Installation position ⇒ page 141 .
❑ Replace if there are signs of scoring and wear
18 - Inner ring for 1st gear permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Check lugs for scoring
19 - Needle bearing
❑ For 1st gear
20 - Synchromeshed gear for 1st gear
21 - Bearing seat with grooved ball bearing
❑ Always replace the grooved ball bearings with the bearing seat
❑ Press off without gear wheel for 5th gear ⇒ page 128
❑ Press off with gear wheel for 5th gear ⇒ page 128
22 - Gearbox

Toledo 2013 ➤
23 - Bolt
24 - Internal ring of the spherical roller bearing
❑ Apply marking prior to removal
❑ Do not confuse with the inner ring of the input shaft roller bearing socket
❑ Installation position: ⇒ page 103
26 - Drift sleeve
27 - 5th gear pinion
❑ Installation position: ⇒ page 102
28 - Spring
29 - Mobile element
30 - Synchro-hub
2. Output shaft 135

Toledo 2013 ➤
2.2 Input shaft: disassembly and assembly

equipment required
♦ Thrust piece - VW 432-

Toledo 2013 ➤
♦ -1- Interior extractor -

Kukko 21/5-
♦ -4- Support bracket -

Kukko 22/1-
ExtractProtected
the roller bearing
by copyright. Copying for private or commercial purposes, in part or in whole, is not
from permitted
the clutch
unless housing
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– On removing the roll‐
er bearing, press the
safety ring -arrow-
with pliers -C-.
A - Counter-support ,
e.g. -Kukko 22/1-
B - Internal puller 30...37
mm , e.g. -Kukko 21/5-
Pressing cylindrical roller bearing into clutch housing

– Support clutch housing using tube - VW 415 A- (not visible in
diagram) directly under bearing mounting.
– On fitting the roller bearing, press the safety ring -arrow- with
pliers -A-.
– Remove the pliers before the roller bearing is in the assembly
position. The securing ring should insert into the groove of the
clutch housing.
Dismantle output shaft
If the 5th gear sprocket -A- cannot be removed by hand.
2. Output shaft 137

Toledo 2013 ➤
Pressing off bearing mounting with deep groove ball bearing and
gear wheel for 5th gear -A-
shaft.
If the 5th gear sprocket can be removed by hand.
Detach the allotment with grooved ball bearings

shaft.
Release the securing ring -1- from its slot

A - Wear protective gloves!
WARNING permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Ensure retaining ring does not spring out uncontrolled.
Pressing off locking collar assembly unit and synchro-hub for 1st
and 2nd gears
– Before pressing off, first remove the locking ring of 2nd gear
synchromeshed gear.

Toledo 2013 ➤
– Remove the securing ring -1- and remove the 3rd gear pinion
-B- by hand.
– Remove the securing rings -2- and -3- and remove the 4th gear
pinion -A- by hand.
Assembling output shaft.
Installation position of 3rd and 4th gear wheel

– Fit 4th gear wheel -A- onto output shaft.
The collar -arrow 1- should face towards the 3rd gear pinion -B-.
– Fit the securing rings -2- and -3-.
– Fit 3rd gear wheel -B- onto output shaft.
The collar -arrow 2- should face towards the 4th gear pinion -A-.
– Fit the securing ring -1-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Checking inner ring for 1st and 2nd gear for wear
– Press inner ring onto tapered seat on selector gear and meas‐
ure gap “a” using a feeler gauge.
Gap “a” Installation dimen‐ Wear limit
sion
1. and 2nd gear 0.75 … 1.25 mm 0.3 mm
Checking 1st and 2nd gear synchro-rings 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” Installation dimen‐ Wear limit
sion
1. and 2nd gear 1.2 … 1.8 mm 0.5 mm
2. Output shaft 139

Toledo 2013 ➤
Installation position of outer ring, inner ring and synchro-ring for

2nd gear
– Place inner ring -A- on synchromeshed gear for 2nd gear.
The tabs -arrow 1- must point to the 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-.
Notches -arrow 4- engage in lugs -arrow 1- of inner ring -A-.
Disassembly and assembly of the mobile element / synchroniser

body unit for 1st and 2nd gear
1- Spring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2- Mobile element respect to the correctness of information in this document. Copyright by SEAT S.A.
3- Synchro-hub
4- Locking piece
After assembly of the unit, the groove on the front edge face
-arrow A- and the higher shoulder -arrow B- of synchro-hub face
outer splines of the locking collar -arrow C-.
Deeper notches -arrow D- for locking pieces in synchro-hub and
notches -arrow E- in locking collar must align.
Assemble the mobile gearshift sleeve / synchroniser body unit of

1st and 2nd gear
fit the elastic rings off-set by 120º. Angled end of spring must
locate in hollow locking piece.

Toledo 2013 ➤
Pressing on locking collar and synchro-hub for 1st and 2nd gears
Groove for selector fork in locking collar points towards 1st gear;
reverse gear splines point towards 2nd gear.
– Turn synchro-ring so that grooves align with locking pieces.
Fit retaining ring.

– Fit the 1st gear securing ring on the mobile sleeve / synchro‐
mesh assembly.
Installation position of outer ring for 1st gear

The tabs -arrows- point towards the teeth of the reverse gear.
Installation position of 1st gear inner ring -A-Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The tabs -arrows 1- insert into the recesses -arrows 2- of the syn‐
chromesh ring -B-.
2. Output shaft 141

Toledo 2013 ➤
Installation position of 1st speed selector gear

The highest collar -A- should face 2nd gear -B-. Notches in shoul‐
der -arrows- engage in lugs of outer ring ⇒ page 141 .
Fit the allotment with grooved ball bearings

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

Toledo 2013 ➤
39 – Final drive - differential

1 Replace seals for flanged shafts with
installed equipment
⇒ “1.1 Renewing oil seal for left flange shaft”, page 143
⇒ “1.2 Renewing seal for right flange shaft”, page 145
1.1 Renewing oil seal for left flange shaft


equipment required
♦ Universal tool - VW 771-
♦ Extraction hook - permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
VW 771/37- respect to the correctness of information in this document. Copyright by SEAT S.A.

♦ Tray - V.A.G 1306-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
1.1.1 Detaching
– Remove left wheel.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 .
– Unbolt drive shaft from flange shaft.
1. Replace seals for flanged shafts with installed equipment 143

Toledo 2013 ➤
– Turn steering to the left.
– If fitted, remove coupling rod -1- from anti-roll bar ⇒ Running

– Unscrew the nuts -arrows- that fix the ball joint to the rocker
arm ⇒ Running gear, axles, steering; Rep. gr. 40 .
– Swing wheel bearing housing outwards.
– Remove the left bearing by guiding it out between the sub‐
frame assembly and the gearbox.
– When doing this, guide drive shaft into wheel housing and se‐
cure to suspension strut with wire. Do not to damage the paint
on the drive shaft during this procedure.
– Place drip tray under the gearbox.

lever.
– Remove flanged shaft together with compression spring.
– Pull out flange shaft oil seal using -VW 771- and -VW 771/37- .
144 Rep. gr.39 - Final drive - differential

Toledo 2013 ➤
1.1.2 Installing
– Fit a new seal as far as possible without tilting.
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease - G 052 128 A1- .
– Fit flanged shaft.
– Secure flange shaft with countersunk bolt
– Fit the drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 .
– Unscrew the ball joint to the rocker arm ⇒ Running gear, axles,
steering; Rep. gr. 40 .
– Secure the coupling rod to anti-roll bar ⇒ Running gear, axles,
steering; Rep. gr. 40 .
– Mount the wheel ⇒ Running gear, axles, steering; Rep. gr.
44 .
– Check gear oil level and top up to lower edge of oil filler hole
if necessary ⇒ page 82 .
– Install noise insulation. ⇒ General body repairs, exterior; Rep.
gr. 50
1.2 Renewing seal for right flange shaft


Toledo 2013 ➤

equipment required
♦ Universal tool - VW 771-
♦ Extraction hook -
VW 771/37-
♦ Inlay socket - 3158-
♦ Tray - V.A.G 1306-
♦ Torque wrench -
V.A.G 1331-
1.2.1 Detaching
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 .
– Turn steering to full right lock.
– Remove drive shaft heat shield, if present -arrows- ⇒ Running
– Unbolt the drive shaft from the flanged shaft ⇒ Running gear,
axles, steering; Rep. gr. 40 .
– Tie up drive shaft as high as possible, taking care not to dam‐
age paint on drive shaft.
– Place drip tray under the gearbox.

Toledo 2013 ➤

lever.
– Remove flanged shaft together with compression spring.
– Pull out flange shaft seal.
Note
♦ Do not damage sleeve -A-. Otherwise, leaks will occur.

♦ Renew sleeve if damaged ⇒ page 109 and ⇒ page 110 .
1.2.2 Installing
– Fit a new seal as far as possible without tilting.
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease - G 052 128 A1- .
– Fit flanged shaft.
– Secure flange shaft with countersunk bolt
– Screw the driveshaft to the flanged shaft ⇒ Running gear,
shafts, steering; Rep. gr. 40 .
– Install the drive shaft heat shield, if present -arrows- ⇒ Run‐

– Check gear oil level and top up to lower edge of oil filler hole
if necessary ⇒ page 82 .
– Install noise insulation. ⇒ General body repairs, exterior; Rep.
gr. 50

Toledo 2013 ➤
2 Differential
⇒ “2.1 Assembly overview - differential”, page 148
⇒ “2.2 Differential: assembly and disassembly”, page 150
⇒ “2.3 Differential: Adjust”, page 156
2.1 Assembly overview - differential

Dismantling and assembling differential ⇒ page 150 .
Note
♦ Heat the inner ring of the roller bearing to 100 °C before fitting.
♦ Replace both conical roller bearings together.
♦ If tapered roller bearings, differential cage, gearbox housing or clutch housing is renewed, adjust differential
⇒ page 156 .
1 - 25 Nm conical bolt
❑ Screw into threaded
piece
2 - Right flange shaft
3 - Compression spring for
flange shaft
❑ Installed behind flange
shafts
4 - Thrust washer
❑ Installation position: the
collar faces the spring
5 - Conical ring
❑ Installation position:
conical side facing the
differential casing
6 - Securing ring permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Keep the following in po‐
sition: conical ring, shim
and pressure spring for
flanged shaft when it is
dismantled
7 - Large planet gear
8 - Threaded piece
❑ Availability ⇒ Electronic
9 - Planet gear shaft
❑ Availability ⇒ Electronic
❑ To remove and install,
first see: removing and installing spring pin, page ⇒ page 155

Toledo 2013 ➤
10 - Small planet gear

❑ Availability ⇒ Electronic parts catalogue (ETKA)
11 - Set of thrust washers
❑ Lubricate with gear oil before installing
12 - Left flange shaft
15 - Inner ring and roller bearing unit
16 - Differential casing
❑ With differential crown
17 - Spring pin
❑ To hold the planetary gear shaft
❑ Is sheared off on removal ⇒ page 156
18 - Inner ring and roller bearing unit
20 - Shim
❑ Determining thickness ⇒ page 156
22 - Gearbox
❑ Bearing seat for tapered roller bearing outer race adapted
❑ Allocation
Protected ⇒ Electronic
by copyright. Copying for private orparts catalogue
commercial purposes, in(ETKA)
part or in whole, is not
23 - respect
clutchto housing
the correctness of information in this document. Copyright by SEAT S.A.
2. Differential 149
Toledo 2013 ➤
2.2 Differential: assembly and disassembly

equipment required
♦ Press die - VW 408 A-
♦ Thrust piece - VW 454-

Toledo 2013 ➤
♦ Assembly sleeve - VW 455-

♦ Extractor tube - 30 - 14-
♦ Tube element - 2040-
2. Differential 151
Toledo 2013 ➤
♦ retention tool - 3067-

♦ Tube - 3259-
♦ Tube for wheel bearing -
3345-
♦ Roller bearing bush extrac‐
tor - V.A.G 1582-
♦ Grip tool - V.A.G 1582/4-
♦ Inside extractor - 1 - Kukko
21/7-
♦ Counter support - 4 - Kukko
22/2-

Toledo 2013 ➤
♦ Pressure plate - 30 - 205-

♦ Torque wrench -
V.A.G 1331- (5…50 Nm)
♦ Grip tool - V.A.G 1582/3-
Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
A - Counter-support , e.g. -Kukko 22/2-
2. Differential 153
Toledo 2013 ➤
Fitting the outer ring of the roller bearing into the gearbox casing
– Support gearbox housing with tube - 3259- directly below
bearing mounting.
Pulling off tapered roller bearing inner races
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
WARNING
– Heat tapered roller bearing inner race to 100 °C before press‐

ing on.
– Support inner race on opposite side using installing sleeve -
VW 455- .
Shoulder of installing sleeve - VW 455- faces towards differential
cage.
Release the outer ring of the conical roller bearing bush -A- from
the clutch casing
– For this, fasten the interior extractor behind the outer ring of
the conical roller bearing.

Toledo 2013 ➤
Pressing tapered roller bearing outer race into clutch housing

– Support gearbox housing with tube for wheel bearing - 3345-
directly below bearing mounting.
Removing the inner ring of the roller bearing

– Before fitting extractor, position spacer sleeve - VW 472/2- and
thrust piece - 3002- on differential housing.
Inserting the inner ring of the roller bearing by pressure
WARNING
– Heat tapered roller bearing
permitted inner by
unless authorised race
SEAT toS.A.
100SEAT°CS.Abefore
does not press‐
guarantee or accept any liability with
ing on.
Arrangement of differential cage to remove and install the clamp‐

ing sleeve
– Check hole for spring pin in differential cage.
Hole Length of spring Spring pin
pin (mm)
-A- 24.0 (short Removing Installing
spring pin) ⇒ page 156 ⇒ page 156
-A- and -B- 36.0 (long spring Removing Installing
pin) ⇒ page 156 ⇒ page 156
continuous 36.0 (long spring Removing Installing
pin) ⇒ page 156 ⇒ page 156
2. Differential 155
Toledo 2013 ➤
Detach the planet gear shaft

When detaching this, the fastening sleeve must be cut.
– Drive remainder of spring pin out of differential cage.
Remove the long clamping sleeve to remove the differential pinion

pin
– Drive clamping sleeve -A- with a drift -B- ∅ 5 mm out of
bore-arrow-in the differential cage.
Note
If there is no bore -arrow- in the differential cage, shear the clamp‐

ing sleeve off ⇒ page 156 .
Installing differential bevel gears

– Lubricate one piece thrust washer with gear oil and install.
– Install both sun wheels and secure (e.g. with flange shaft).
– Insert planet pinions offset 180° and pivot into position.
– Insert the planet gear shaft -arrow A- to the first planet gear.
– Place threaded pieces - arrows B - in the sun gears.
Installing spring pin for differential pinion pin

– Align hole in differential pinion pin with hole in differential cage.
– Drive clamping sleeve -1- in with a drift until dimension
-a- = 2.5 mm is reached.
• The clamping sleeve -1- must not touch the clutch housing.
2.3 Differential:
by SEAT S.A.Adjust
permitted unless authorised SEAT S.A does not guarantee or accept any liability with

Toledo 2013 ➤

equipment required
♦ Final measurement plate -
VW 385/17-
♦ Universal bracket for gauge
- VW 387-
2. Differential 157
Toledo 2013 ➤

♦ Extractor tube - 30 - 14-
♦ Tube element - 2040-
♦ Tube - 3259-
♦ Tube for wheel bearing -
3345-
♦ Torque wrench -
V.A.G 1331-
♦ Dial gauge
♦ Pressure plate - 30 - 205-
It is necessary to readjust the differential when the following com‐

ponents are renewed: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Gearbox permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ clutch housing
♦ Differential casing
or the
♦ Differential roller bearings

Toledo 2013 ➤
– Adapt the outer of the conical roller bearing (mobile pinion) into
the gearbox, where applicable, use shim S1 (always a thick‐
ness of 1 mm).
Note
Inner and outer tapered roller bearing races are paired. Do not
mix them up.
– Insert the outer ring of the conical roller bearing (opposite side
to crown) into the clutch hosing without the shim.
– Insert differential in gearbox housing.
– Fit clutch housing in place and tighten 5 bolts to torque
⇒ Item 3 (page 88) .

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

A - 30 mm gauge extension
– Adjust the dial gauge to “0” with a pre-tension of 1 mm.
– Move the differential up and down, read the play in the gauge
and note it. (Example: 1.50 mm.)
2.3.1 Determining thickness of shim S2

The specified bearing preload is obtained for S2 by adding a con‐
stant value for preload (0.35 mm) to the measured value.
Example:
Measured value 1.50 mm
+ Pressure value (const. value) 0.35 mm
Thickness of shim S2 = 1.85 mm
2. Differential 159
Toledo 2013 ➤
– Remove the clutch housing and release the outer ring of the
conical roller bearing -A-.
– See ⇒ Electronic catalogue of spare parts “ETKA” to allocate
thrust rings.
The various thicknesses make it possible to achieve the exact
shim thickness required.
If the thickness required for the thrust ring is greater than that
indicated in the ⇒ Electronic catalogue of spare parts“ETKA” , 2
rings with a total thickness equal to the required thickness may
be used.
– Insert correct S2 shim (in example 1.85 mm) and press ta‐
pered roller bearing outer race into clutch housing again.
– Insert the coupling housing and tighten bolts to torque, Pos. 3
⇒ page 88 .

D3E804F5187-6-Speed Manual Gearbox 02U

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D3E804F5187-6-Speed Manual Gearbox 02U

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Service

Service Department. Technical Information

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Copyright © 2015 Seat S.A D3E804F5187

2.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

2.1 Output shaft: Installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

1.1 Safety precautions when working on ve‐

On vehicles with start-stop system, there is the risk of injury

1.2 Safety precautions when using testers

There is a risk of accident from unintended motion and insuf‐

Engine code and manufacture date of gearbox

The gearbox identification letters are also written on the technical

2 Rep. gr.00 - Technical data

3 Overview - power transmission

3. Overview - power transmission 3

4 Rep. gr.00 - Technical data

4.1 Filling quantity

4.2 Allocation gearbox - engine

Manual gearbox 6-speed 02U

Manual gearbox 6-speed 02U

4.3 Calculation of gear ratios

6 Rep. gr.00 - Technical data

5.1 General notes

♦ Do not over-expand safety rings.

8 Rep. gr.00 - Technical data

♦ Do not interchange. When reusing synchro-rings, always fit to

5.2 Contact corrosion

5.3 Gaskets, seals

5.4 Bolts, nuts

♦ It is important to ensure at all bolted connections that the con‐

10 Rep. gr.00 - Technical data

6.1 Fitting location overview - electrical

6.1.1 Fitting location overview - electrical components, manual gearbox

1 - Reversing light switch - F4-

6.1.2 Fitting location overview - electrical

Checking clutch pedal switch - F36-

12 Rep. gr.00 - Technical data

1.1 Overview - clutch actuation

1. Clutch mechanism: repairs 13

I - Assembly overview - pedal

14 Rep. gr.30 - Clutch

1.2 Assembly overview - pedal cluster

1.2.1 Assembly overview - pedal cluster (vehicles up to MY16)

1 - Bulkhead of the plenum

1. Clutch mechanism: repairs 15

Removing and installing extension spring

16 Rep. gr.30 - Clutch

1.2.2 Assembly overview - pedal cluster (vehicles from MY16)

1. Clutch mechanism: repairs 17

❑ removing and installing ⇒ page 29

1.3 Assembly overview - hydraulics (LHD)

1 - Brake fluid reservoir

18 Rep. gr.30 - Clutch

10 - Pipe and hose assembly

Levering retaining clip -A- off in direction of arrow

Seals and O-rings for pipe and hose lines