Audi Workshop Service and Repair Manuals

Dismantling and assembling selector mechanism in gearbox

Special tools and workshop equipment required

t	Guide pin -VW 439-

t	Thrust plate -VW 401-

t	Press tool -VW 408 A-

t	Thrust plate -VW 447 i-

t	Thrust piece -3129-

t  -1-Internal puller -Kukko 21/3-

Selector mechanism in gearbox - exploded view of components

1 -	Selector shaft

q	From gearbox build date 04 09 0, detent sleeve modified so that when shifting down from 5th gear to 4th gear the selector shaft is guided into the 4th gear selector gate → Fig.

2 -	Check ring

3 -	Ball sleeve

q	Removing → Fig.

q	Pressing in → Fig.

4 -	Selector mechanism cover

q	Additional bolt fitted from gearbox build date 04 09 0 so that when shifting down from 5th gear to 4th gear the selector shaft is guided into the 4th gear selector gate → Fig.

5 -	Reversing light switch -F4-

q	Lightly coat lug with MoS2 grease

q	Tighten to 20 Nm

6 -

Cap

q	For gearbox breather

7 -	Relay lever

q	Installation position → Fig.

8 -	Bearing bush

9 -

Oil seal

q	Lever out with screwdriver

q	Installing → Fig.

10 -	Securing clip

11 -	Hexagon nut, 20 Nm

q	Self-locking

q

Renew

12 -	Selector shaft lever

q	Install so that gap in splines aligns with selector shaft

q	Can be renewed with selector mechanism installed

q	Installation position → Fig.

13 -	Cover plate

q	From gearbox date 06 08 1 with retainer for selector shaft → Fig.

Pulling ball sleeve out of selector mechanism cover –  Before pulling out ball sleeve, destroy plastic cage and remove balls. A -  Internal puller 18.5 ... 23.5 mm -Kukko 21/3-

Driving ball sleeve into selector mechanism cover

Installing oil seal (insert onto stop)

Modified selector mechanism cover and selector shaft t  From gearbox build date 04 09 0, bolt -2- is fitted in selector mechanism cover -1- (tightening torque 15 Nm). t  The detent sleeve on the selector shaft has been fitted with a ramp -3- for this purpose. t  When shifting down from 5th gear to 4th gear, bolt -2- guides the selector shaft by means of ramp -3- into 4th gear selector gate.

Selector shaft and cover plate modified t  From gearbox build date 06 08 1 with recesses on selector shaft -A-. t  Cover plate is fitted with spring -B-. t  The spring -B- in the cover plate engages into one of the recesses in the selector shaft -A- when a forward gear is engaged.