Volkswagen Workshop Service and Repair Manuals

Repairing selector forks

Special tools and workshop equipment required

t	Pressure plate -VW 402-

t	Thrust piece -3290/1-

t	Assembly tool -3301-

t	Thrust piece -VW 431-

t	Spacer sleeve -VW 472/2-

t	Drift -10 - 206-

t  Removal lever -80–200-

t  Drift -10 - 508-

t  Clamp -2070-

Identifying selector segments Dimension -a- 1 -  1st and 2nd gear selector segments = 11.4 mm 2 -  3rd and 4th gear selector segments = 7.7 mm 3 -  5th gear selector segments = 12.1 mm

Removing lock washer –  Clamp selector fork in vice with protective jaw covers -B-. –  Lever off lock washer -A- in direction of arrow.

Installing lock washer –  Press lock washer into groove of selector segment using socket and spinner handle.   Note After lock washer is installed, selector segment must still rotate freely. A -  Spinner handle with 10 mm socket B -  Protective jaw covers

Removing angular contact ball bearing   Note When removing and installing angular contact ball bearing, do not bend selector forks.

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

Pulling angular contact ball bearing into selector fork to stop Depression in thrust piece -3290/1- faces ball bearing.

Selector fork with selector segments installed

	Dim. -a- (mm)
1st/2nd gear selector fork	87.2 …87.4
3rd/4th gear selector fork	93.6 …93.8

Selector segment assignment → Fig..