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-

t	Assembly tool -3301-

t	Press tool -VW 431-

t	Spacer sleeve -VW 472/2-

t	Drift -10 - 206-

t  Removal lever -80–200-

t  Assembly mandrel -10 - 508-

t  Tensioning device -2070-   Note 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 -	Selector fork cluster with selector plates

2 -	3rd/4th gear detent segment

q	Identification → Fig.

q	Detent segment should turn freely after installation.

3 -	Angular contact ball bearing

q

4x

q	Removing → Fig.

q	Pressing inner race into outer race → Fig.

q	Installing → Fig.

4 -	Lock washer

q	Always renew

q	Removing → Fig.

q	Installing → Fig.

5 -	1st/2nd gear detent segment

q	Identification → Fig.

q	The segment must rotate freely after installing the lock washer

q	Selector fork with detent segment

6 -	5th/6th gear selector fork with detent segments

q	Detent segments are inseparably joined with selector fork

q	Identification → Fig.

7 -

Pivot pin

q	for 5th/6th gear selector fork

Identification of detent segments and 5th/6th gear selector fork with detent segments Dimension -a- 1 -  Detent segments 1st/2nd gear = 10.0 mm 2 -  Detent segment 3rd/4th gear = 78.6 mm 3 -  5th/6th gear selector fork with detent segments = 79.5 mm

1st/2nd gear selector fork with detent segments Dimension -a- = 78 mm.

Removing lock washer –  Secure selector fork in vice with protective jaw covers -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 Detent segment should turn freely after lock washer is installed. A - Socket driver, 10 mm B - Soft jaws

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

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

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