SEAT Workshop Service and Repair Manuals

Gear box forks: repairing Special tools and workshop equipment required

t  Gearbox repair set -U-40300-

t  Circlip opening pliers -A-81124-

1 -	Gearbox commutation bolt

q	Identification → Fig.

q	After installing the clamping washer, the commutation bolts must be able to move slightly

2 -	Clamping washer

q	Remove the clamping washer, levering carefully with a screwdriver

q	Fit → Fig.

q	Always renew

3 -	Fork for 5th gear

q	Adjusting → Fig.

4 -	Connection opening for 5th gear

5 -

Bolt

q

25 Nm

6 -	Connection guide for 5th gear

7 -	Safety ring

8 -

Washer

9 -	Connection guide for 3rd/4th gear

10 -	Connection guide for 1st/2nd gear

11 -	Connection guide for reverse gear

12 -	Fork for 3rd/4th gear

q	With gearbox commutation bolt → Fig.

13 -	Gearbox commutation bolt

q	Identification → Fig.

q	After installing the clamping washer, the commutation bolts must be able to move slightly

14 -	Ball bearing

15 -	Inner ring of ball bearing

q	Remove → Fig.

q	Fit → Fig.

16 -	Fork for 1st/2nd gear

q	With gearbox commutation bolts → Fig.

17 -	Gearbox commutation bolt

q	Identification → Fig.

q	After installing the clamping washer, the commutation bolts must be able to move slightly

18 -	Safety ring

19 -	Reverse gear fork support

20 -	Reverse gear

21 -

Spring

22 -	Sliding piece

Identification of commutation bolts for gearbox forks Dimension -a- 1 -  1st and 2nd gears = 12.1 mm 2 -  3rd and 4th gears = 7.7 mm 3 -  5th gear = 12.1 mm

Installing clamping washers –  Press the clamping washer in the groove of the bolt with a handled socket spanner.   Note! After installing the pressure washer, the commutation bolts must be able to move slightly. A -  Handled socket spanner, e/c 10 mm B -  Protected jaws

Removing the inner ring of the ball bearing   Note! In removing and installing the inner rings, do not bend the forks.

Fit as far as the stop of the inner ring of the ball bearing   Note! In removing and installing the inner rings, do not bend the forks.

Forks with gearbox commutation bolts installed

	Dimension -a- (mm)
Fork for 1st/2nd gear	87.2...87.9
Fork for 3rd/4th gear	96.0...96.7

Identification of commutation bolts for gearbox forks → Fig..