Reconditioning a gearbox on a SEAT Leon MK2 is a complex task that requires precision, patience, and the right tools. click here for more details on the download manual…..

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Below is a detailed guide on the tools and steps involved in this process.

### Tools Required for Gearbox Reconditioning

– **Socket Set**: A comprehensive set of sockets (metric sizes) to remove various bolts and fasteners on the gearbox.
– **Ratchet and Extensions**: A ratchet with extensions is essential for accessing tight spaces around the gearbox.
– **Torque Wrench**: For reassembling components to the manufacturer’s specifications, ensuring proper torque settings.
– **Screwdrivers**: A set of flathead and Phillips screwdrivers for removing screws and clips.
– **Pliers**: Needle-nose and adjustable pliers for gripping and manipulating various components.
– **Seal Puller**: A specialized tool to remove seals without damaging surrounding components.
– **Gasket Scraper**: For removing old gaskets and ensuring a clean surface for new ones.
– **Cleaning Solvent**: To clean components and remove oil, dirt, and debris from the gearbox.
– **Magnetic Tray**: To keep small bolts and components organized during disassembly.
– **Gearbox Oil**: New oil for the gearbox post-reconditioning; ensure it meets OEM specifications.
– **Replacement Parts**: Gaskets, seals, bearings, and any worn components should be replaced to ensure proper operation.
– **Work Light**: Adequate lighting will help you see clearly while working on the gearbox.
– **Engine Hoist or Jack**: To support the vehicle safely while you work underneath it.
– **Gear Puller**: For removing gears and other press-fit components.
– **Calipers or Micrometer**: For measuring components to check for wear and tolerances.
– **Safety Gear**: Gloves, goggles, and steel-toed boots for personal protection during the job.

### Steps for Gearbox Reconditioning

– **Preparation**:
– Ensure the car is parked on a flat surface and is securely lifted using a jack or hoist.
– Disconnect the battery to prevent any electrical issues during the process.

– **Remove the Gearbox**:
– Drain the gearbox oil using a drain pan to prevent spills.
– Disconnect the driveshafts by unbolting them from the wheel hubs and sliding them out of the gearbox.
– Detach any electrical connectors and sensors attached to the gearbox.
– Remove the gearbox mounting bolts and any additional brackets that may be obstructing removal.
– Carefully slide the gearbox out from the engine bay, ensuring no components are left connected.

– **Disassemble the Gearbox**:
– Place the gearbox on a clean workbench.
– Remove the casing bolts and gently split the gearbox halves apart.
– Take note of the arrangement of gears, shafts, and other components as you remove them.
– Use a seal puller to remove old seals and gaskets without scratching the metal surfaces.

– **Inspect Components**:
– Check all gears, bearings, and shafts for wear or damage using calipers or a micrometer.
– Replace any worn or damaged components with new parts as needed.
– Clean all components using a cleaning solvent to remove old oil and grime.

– **Reassemble the Gearbox**:
– apply new gaskets and seals to the appropriate surfaces before reassembly.
– Carefully place gears and shafts back in their original positions.
– Reattach the gearbox casing, ensuring it is seated correctly and all bolts are tightened to the specified torque.

– **Reinstall the Gearbox**:
– Lift the gearbox back into place in the vehicle.
– Reconnect the mounting bolts and ensure everything is aligned properly.
– Reattach the driveshafts, electrical connectors, and any other components that were removed.
– Fill the gearbox with the appropriate type and amount of oil.

– **Final Checks**:
– Reconnect the battery and perform a visual inspection to ensure everything is properly connected.
– Start the vehicle and check for any leaks or unusual noises.
– Test drive the vehicle to ensure smooth gear changes and proper operation of the gearbox.

By following these detailed steps and using the appropriate tools, you can successfully recondition the gearbox on a SEAT Leon MK2. Always refer to the manufacturer’s service manual for specific details and torque specifications related to your vehicle.
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