Audi Workshop Service and Repair Manuals

Dismantling and assembling selector forks

Special tools and workshop equipment required

t	Thrust plate -VW 402-

t	Press tool -VW 408 A-

t	Press tool -VW 431-

t	Thrust plate -VW 447 H-

t	Spacer sleeve -VW 472/2-

t	Assembly mandrel -10 - 206-

Special tools and workshop equipment required

t  Removal lever -80 - 200-   Note t  Selector plates and selector forks are machined together (drilled). Always renew the complete selector mechanism if necessary. t  Do not confuse selector plate for 1st/2nd gear → Item with selector plate for 3rd/4th gear → Item.

1 -	3rd/4th gear selector fork

2 -	Angular contact ball bearing

q	Removing → Fig.

q	Pressing in → Fig.

3 -	Lock washer

q	Removing → Fig.

q	Installing → Fig.

4 -	Securing clip

5 -

Washer

6 -	Detent segment

q	Identification → Fig.

q	After installing circlip the detent segment must rotate freely

7 -	Detent segment

q	Identification → Fig.

q	After installing circlip the detent segment must rotate freely

8 -	5th gear selector plate

9 -	3rd/4th gear selector plate

10 -	1st/2nd gear selector plate

11 -	Reverse gear selector plate

12 -

Pin

13 -	Reverse gear selector fork

14 -	Reverse gear mounting

15 -	Securing clip

16 -	1st/2nd gear selector fork

17 -	Detent segment

q	Identification → Fig.

q	The segment must rotate freely after installing the lock washer

18 -	5th gear selector fork

19 -	Detent segment

q	Identification → Fig.

q	The segment must rotate freely after installing the lock washer

20 -

Pivot pin

q	for 5th gear selector fork

Removing angular contact ball bearing   Note Do not bend selector forks when removing and installing the ball bearing.

Pressing in angular contact ball bearing onto stop

Removing lock washer –  Secure selector fork in vice with soft jaws -B-. –  Lever off lock washer -A- in direction of -arrow-.

Installing lock washer –  Push lock washer into groove in detent segment using socket driver.   Note After installing circlip the lock washer must rotate freely. -A- Socket driver, 10 mm -B- Protective jaw covers

Identification of detent segments Distance -a-

1 -	Detent segment for 1st and 2nd gear and short detent segment for 3rd and 4th gear	=	10.2
2 -	Long detent segment for 3rd and 4th gear	=	10.2
3 -	5th gear detent segment	=	6.0