Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling 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-

It is not necessary to dismantle the selector fork group → Item in order to dismantle and assemble selector segments, lock washers and angular contact ball bearings.

1 -	Selector fork group with selector plate

2 -	Selector segment for 3rd and 4th gear

q	After installation, selector segment must still rotate freely

q	Identification → Fig.

3 -	Angular contact ball bearing

q

Qty. 4

q	Removing → Fig.

q	Press 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 selector segment

q	Identification → Fig.

q	After lock washer is installed, segment must still rotate freely

q	Selector fork with selector segment → Fig.

6 -	Selector fork for 5th and 6th gears with selector segments

q	Selector segment is permanently connected to selector fork.

q	Identification → Fig.

7 -

Pivot pin

q	For selector fork for 5th and 6th gears

Identification of selector segments and selector fork for 5th and 6th gear with selector segments. Dimension -a- 1 -  Selector segment for 1st and 2nd gears = 10.0 mm 2 -  Selector segment for 3rd and 4th gears = 78.6 mm 3 -  Selector fork for 5th and 6th gears with selector segments = 79.5 mm

Selector fork for 1st and 2nd gears with selector segments Dimension -a- = 78 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.