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- from assembly tool -3290-

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-

Identification of detent segments and 5th gear selector fork with detent segments Dimension -a- 1 -  Detent segments 1st/2nd gear = 10.2 mm 2 -  Detent segment 3rd/4th gear = 78.6 mm 3 -  5th/6th gear selector fork with detent segments = 79.5 mm

Separate detent segments for 3rd/4th gear -A- Detent segments should turn freely after installation.

Identification of separate detent segments for 3rd/4th gear 1 -  Short detent segment for 3rd/4th gear: -a- = 10.2 mm 2 -  Long detent segment for 3rd/4th gear: -a- = 10.2 mm

1st/2nd gear selector fork with detent segments Dimension -a- = 75 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 –  Press lock washer into groove on detent segment using socket attachment. A -  Socket (10 mm) B -  Protective jaw covers   Note Detent segment should turn freely after lock washer is installed.

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.