Audi Workshop Service and Repair Manuals

Dismantling and assembling selector forks

Special tools and workshop equipment required

t	Thrust plate -VW 402-

t	Thrust piece -3290/1- from assembly tool -3290-

t	Press tool -VW 431-

t	Assembly tool -3301-

t	Spacer sleeve -VW 472/2-

t	Drift -10-206-

t  Removal lever -80-200-

t  Assembly drift -10-508-

t  Tensioning device -2070-

Selector forks - exploded view of components

The selector fork cluster → Item does not have to be dismantled in order to remove and install detent segments, lock washers and angular contact ball bearings.

1 -	5th gear detent segment

q	Identification → Fig.

q	Must rotate freely after lock washer is installed

2 -	Lock washer

q

Renew

q	Removing → Fig.

q	Installing → Fig.

3 -	5th gear selector fork

q	Adjusting → Anchor

4 -	Bolt, 25 Nm

5 -	5th gear selector jaw

6 -	Angular contact ball bearing

q

4 x

q	Removing → Fig.

q	Pressing inner race into outer race → Fig.

q	Installing → Fig.

7 -	Selector fork cluster with selector plates

q	Dimensions → Fig.

8 -	1st/2nd gear detent segment

q	Identification → Fig.

q	The segment must rotate freely after installing the lock washer.

9 -	3rd/4th gear detent segment

q	Identification → Fig.

q	The segment must rotate freely after installing the lock washer.

10 -	Sliding piece

11 -

Spring

12 -	Reverse gear selector fork

13 -	Support for reverse gear selector fork

14 -

Circlip

Identification of detent segments 1 -  Detent segments, 1st/2nd gear: dimension -a- = 12.1 mm  -  Detent segments, 1st/2nd gear in combination with modified synchromesh ( → Chapter): dimension -a- = 11.4 mm 2 -  Detent segments, 3rd/4th gear: dimension -a- = 7.7 mm 3 -  Detent segments, 5th gear: dimension -a- = 12.1 mm   Note The shorter detent segments for 1st/2nd gear can also be installed on gearboxes of the earlier type.

Selector forks with detent segments installed l  Detent segments, 1st/2nd gear: dimension -a- = 87.2 ... 87.9 mm l  Detent segments, 3rd/4th gear: dimension -a- = 96.0 ... 96.7 mm For identification of detent segments → Fig.

Removing lock washer –  Clamp selector fork in vice, using jaw protectors -B-. –  Lever off lock washer -A- in direction of -arrow-.

Installing lock washer –  Press lock washer into groove on detent segment using socket driver. A -  Socket driver (10 mm) B -  Jaw protectors l  Detent segment should turn freely after lock washer is installed.

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

Pressing inner race of angular contact ball bearing into outer race l  Inner race -A- must engage positively in outer race.

Pulling angular contact ball bearing into selector fork (insert onto stop) l  Recess in thrust piece -3290/1- points towards ball bearing.