SEAT Workshop Service and Repair Manuals

Gearbox forks: repair Special tools and workshop equipment required

t  Gear repair case -U-40300-

t  Pliers for opening elastic rings -A-81124-

Assembly Chart

1 -	Gear switch anchor bolt

q	Identification → Fig.

q	After assembling the safety washer, the blocks must be able to move slightly.

2 -	Pressure washer

q	Separate the pressure washer by levering carefully with a screwdriver.

q	Assembly → Fig.

q	Always replace

3 -	5th gear fork

q	Adjust → Fig.

4 -	5th gear connection hub

5 -	Bolt, 25 Nm

6 -	5th gear connection guide

7 -	Safety ring

8 -

Washer

9 -	Connection guide for 3rd and 4th gears

10 -	Connection guide for 1st and 2nd gears

11 -	Connection guide for reverse gear

12 -	Fork for 3rd and 4th gears

q	With switch anchor bolt for gears → Fig.

13 -	Switch anchor bolt for gears

q	Identification → Fig.

q	After the assembly of the safety wa-sher, the blocks must be able to move slightly

14 -	Ball bearing

15 -	Inner ring of the ball bearing

q	Dismount → Fig.

q	Fitting → Fig.

16 -	1st/2nd gear fork

q	With blocks for the gearbox forks → Fig.

17 -	Reverse gear switch anchor bolt

q	Identification → Fig.

q	After the assembly of the safety washer, the blocks must be able to move slightly.

18 -	Safety ring

19 -	Support for reverse gear fork

20 -	Reverse gear fork

21 -

Spring

22 -	Sliding block

Identifying the blocks for the gearbox forks Gap height -a- 1 -  1st and 2nd gears = 12.1 mm 2 -  3rd and 4th gears = 7.7 mm 3 -  5th gear = 12.1 mm

Assembly of the pressure washers –  Press down the pressure washer into the groove for the block with a box spanner with a handle.   Note! After the assembly of the safety washer, the blocks should be able to move slightly.. A -  Box spanner with handle, with 10 mm B -  Protective grips

Dismount the ball bearing   Note! When dismounting and assembling the bearings, do not bend the forks.

Fit in to the top of the inner ring of the ball bearing   Note! When dismounting and assembling the bearings, do not bend the forks.

Fork with blocks mounted

	Gap height -A- (mm)
1st and 2nd gear fork	87.2 … 87.9
3rd and 4th gear fork	96.0 … 96.7

Identification of the blocks for the gearbox forks → Fig..