Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ VW 402 Thrust plate
• ◆ 3290/1 Press piece from assembly tool 3290
• ◆ 3301 Assembly tool
• ◆ VW 431 Press piece
• ◆ VW 472/2 Spacer sleeve
• ◆ 10-206 Drift

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ 80-200 Lever

• ◆ 10-508 Assembly mandrel

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ 2070 Tensioning device

Note:

• ◆ The selector fork group (item 7 ) need not be dismantled to remove and install selector segments, lock washers and angular contact ball bearings.

• 5th gear selector segment
• ◆ Identification => Fig.1
• ◆ After installing lock washer the selector segment must rotate freely
• Lock washer
• ◆ Always renew
• ◆ Removing => Fig.2
• ◆ Installing => Fig.3
• 5th gear selector fork
• ◆ Adjusting
• Bolt, 25 Nm
• 5th gear selector jaw

• Angular contact ball bearing
• ◆ Qty. 4
• ◆ Removing => Fig.4
• ◆ Press inner race into outer race
  => Fig.5
• ◆ Installing => Fig. 6
• Selector fork group and selector plates
• 1st/2nd gear selector segment
• ◆ Identification => Fig.1
• ◆ After installing lock washer the segment must rotate freely
• 3rd/4th gear selector segment
• ◆ Identification => Fig.1
• ◆ After installing lock washer the segment must rotate freely
• Sliding piece

• Spring
• Reverse gear selector fork
• Support for reverse gear selector fork
• Circlip

→ Fig.1     Identifying selector segments

Dimension -a-

1 - 1st and 2nd gear selector segments = 12.1 mm

1st and 2nd gear selector segments in combination with modified synchronisation (=> page 35-52 ) = 11.4 mm

Shorter selector segments can also be installed in older generation gearboxes.

2 - 3rd and 4th gear selector segments = 7.7 mm

3 - 5th gear selector segments = 12.1 mm

→ Fig.2 Removing lock washer

• ‒ Secure selector fork in vice with jaw protectors -B-.
• ‒ Lever off lock washer -A- in direction of arrow.

→ Fig.3     Installing lock washer

• ‒ Press lock washer into selector segment groove using socket and drive handle.

Note:

After installing the lock washer the selector segment must rotate freely.

A - Socket driver, 10 mm A/F

B - Jaw protectors

→ Fig.4     Removing angular contact ball bearing

Note:

When removing and installing the inner races, do not bend selector forks.

→ Fig.5     Pressing angular contact ball bearing inner race -A- into outer race

The inner race must engage with outer race.

→ Fig.6     Pulling angular contact ball bearing into selector fork onto limit stop

The press piece recess 3290/1 faces towards ball bearing.

→ Fig.7     Selector fork with selector segments installed

Selector segment assignment => Fig.1 .