volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling selector forks > < Servicing gearbox housing and clutch housing
5 Speed Manual Gearbox 02C four wheel drive
Dismantling and assembling gearbox selector mechanism
Dismantling and assembling gearbox selector mechanism
 
N34-0054
  • Selector shaft
  • Stop ring
  • Ball sleeve
    • ◆ Removing => Fig.1
    • ◆ Pressing in => Fig.2
  • Oil seal
    • ◆ Lever out with screwdriver
    • ◆ Installing => Fig. 3
  • Selector mechanism cover
 
N34-0054
  • Sleeve
    • ◆ The lug points to reverse light switch
    • ◆ Lightly coat lug with MoS2 grease
  • Hexagon nut, 25 Nm
    • ◆ Self-locking
    • ◆ Always renew
  • Housing
    • ◆ For reverse light switch
  • bolt
  • Cap
    • ◆ For gearbox breather
  • Sleeve
    • ◆ Knock-in onto stop
 
N34-0054
  • Gear selector lever
    • ◆ Install so that the master spline aligns with selector shaft
    • ◆ Can be replaced with the selector mechanism installed
    • ◆ Installation position
    • ◆ Replacing => Fig. 4
  • Relay lever
    • ◆ Installation position
  • Nut, 15 Nm
  • Actuating arm
    • ◆ With axis pin for mounting relay lever
    • ◆ Installation position => Page 34-9
  • Bolt
    • ◆ Press into actuating arm
 
N34-0054
  • O-ring
    • ◆ Pull onto actuating arm axis pin
  • Spacer
    • ◆ Press into relay lever
  • Locking bolt, 40 Nm
  • End cover
 
V34-2021

→ Fig.1     Removing ball sleeve from selector mechanism cover

  • ‒ Before pulling out ball sleeve, destroy plastic cage and remove balls.

A - Internal extractor, e.g. Kukko 21/3, 18.5 ... 23.5 mm

 
V34-2022

→ Fig.2     Knocking ball sleeve into selector mechanism cover

 
V34-2023

→ Fig.3     Installing oil seal onto stop

 
N34-0055

→ Fig.4     Replacing gear selector lever

  • ‒ Press selector shaft down (arrow -1-).
  • ‒ Twist gear selector lever round (arrow direction -2-) and pull out in arrow direction -3-.

Dismantling and assembling selector forks > < Servicing gearbox housing and clutch housing