Audi Workshop Service and Repair Manuals

Exploded view - dismantling and assembling selector forks

Special tools and workshop equipment required

t	Thrust plate -VW 402-

t	Thrust piece -3290/1- of 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-

The selector fork cluster ( → Item) does not have to be dismantled in order to remove and install detent segments, lock washers and angular contact ball bearings.

1 -	5th gear detent segment

q	Identification → Fig.

q	Detent segment should turn freely after lock washer is installed

2 -	Lock washer

q	Always renew

q	Removing → Fig.

q	Installing → Fig.

3 -	5th gear selector fork

q	Adjusting →

4 -

Bolt

q

25 Nm

5 -	5th gear selector jaw

6 -	Angular contact ball bearing

q

4x

q	Removing → Fig.

q	Pressing inner race into outer race → Fig.

q	Installing → Fig.

7 -	Selector fork cluster with selector plates

q	Check selector fork with detent segments installed → Fig.

8 -	1st/2nd gear detent segment

q	Identification → Fig.

q	Detent segment should turn freely after lock washer is installed

9 -	3rd/4th gear detent segment

q	Identification → Fig.

q	Detent segment should turn freely after lock washer is installed

10 -	Sliding piece

11 -

Spring

12 -	Reverse gear selector fork

13 -	Support for reverse gear selector fork

14 -

Circlip

Identification of detent segments Distance -a- -1- 1st and 2nd gear detent segments = 12.1 mm Detent segments, 1st/2nd gear in combination with modified synchromesh ( → Chapter) = 11.4 mm. The shorter detent segments can also be installed on gearboxes of the earlier type. -2- 3rd and 4th gear detent segments = 7.7 mm -3- 5th gear detent segments = 12.1 mm

Removing lock washer –  Secure selector fork in vice with soft jaws -B-. –  Lever off lock washer -A- in direction of arrow.

Installing lock washer –  Push lock washer into groove in detent segment using socket driver.   Note Detent segment should turn freely after lock washer is installed. A -  Socket driver, 10 mm B -  Jaw protectors

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.

Selector forks with detent segments installed

	Dimension -a- (mm)
1st/2nd gear selector fork	87.2…87.9
1st/2nd gear selector fork in combination with modified synchromesh ( → Chapter)	88.4…89.1
3rd/4th gear selector fork	96.0…96.7

For identification of detent segments → Fig.