Audi Workshop Service and Repair Manuals

Dismantling and assembling selector mechanism in gearbox

Special tools and workshop equipment required

t	Drift -VW 295-

t	Adapter -VW 295 A-

t	Thrust plate -VW 401-

t	Tube -VW 420-

t	Tube -VW 423-

t	Spacer sleeve -VW 472/2-

t  Multi-purpose tool -VW 771-

t  -1-Internal puller 23.5…30 mm, e.g. -Kukko21/4-

Installation position of complete selector mechanism in gearbox → Fig.

1 -	Locking unit for 5th gear and reverse gear

q	Removing and installing →

2 -

TORX bolt

q

10 Nm

3 -

O-ring

q	Always renew

4 -	Stop bolt (right-side)

q

40 Nm

5 -

Washer

6 -	Relay shaft

7 -

Washer

8 -	Stop bolt (left-side)

q

40 Nm

9 -	Detent segment

10 -

TORX bolt

q

25 Nm

11 -	Spring pin

12 -	Selector fork for 5th gear and reverse gear

q	Installation position → Fig.

13 -	Selector rods for 1st/2nd and 5th/reverse gear

14 -	Ball sleeve

q	Removing and installing → Fig.

15 -	Selector fork for 1st and 2nd gear

16 -

Follower

q	Installation position → Fig.

17 -	Bearing bush for 3rd and 4th gear

q	Pulling out → Fig.

q	Driving in → Fig.

18 -	Ball sleeve

q	Lever off the selector rod with a screwdriver

q	Press onto the selector rod

19 -	Selector rod for 3rd and 4th gear

20 -	Selector fork for 3rd and 4th gear

21 -	Spring pin

22 -

Cover

q	For selector shaft

23 -

TORX bolt

q

20 Nm

24 -	Selector shaft

25 -

Oil seal

q	Lever out with screwdriver

q	Use tube -VW 420- to insert

q	Installation position → Fig.

Installation position of selector fork for 5th and reverse gear and follower for selector rod t  Dimension -a- = 55 mm t  Dimension -b- = 60 mm

Removing and installing ball sleeve

Pulling out bearing bush for 3rd and 4th gear selector rod A -  Internal puller 23.5...30 mm, e.g. -Kukko 21/4- together with multi-purpose tool -VW 771-

Driving in bearing bush for 3rd and 4th gear selector rod onto stop

Installation position of oil seal –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-. –  Lightly oil outer circumference of oil seal. –  Use tube -VW 420- to insert oil seal. t  Dimension -a- = 1 mm

Installation position of complete selector mechanism in gearbox: 1 -  Selector fork for 5th gear and reverse gear 2 -  Selector fork for 3rd gear and 4th gear 3 -  Selector fork for 1st gear and 2nd gear 4 -  Relay shaft 5 -  Detent mechanism 6 -  Selector shaft Removing and installing locking unit for 5th gear and reverse gear

–  Remove heat shield -arrow 2- above drive shaft (right-side). –  Detach heat shield -arrow 1- above drive shaft (right-side) and pivot downwards.

–  Remove locking unit -arrow-.

Assembling locking unit: –  Insert spring -1- into housing -2- and, while exerting light pressure, turn spring to the left until it locates in the base of the housing. –  Insert bush -3- onto the spring so that the bent end of the spring locates in the groove. –  Push bush -3- against spring and turn approx. one turn to the left, until the lug on the bush aligns with the groove in the housing -2-. –  Press lug on bush -3- onto stop in the groove in the housing -2-. –  Turn bush -3- to right and release; the bush -3- will spring into position.

Installation position of bush: –  The lug -arrow A- on the bush must always be opposite the groove in the housing -arrow B-. Checking installation position: –  Turn bush to left and release. l  The bush should spring back into position; the lug must be against the stop (direction indicated by -arrow A-).

Installation position of complete locking unit in gearbox: The recess -arrow A- faces bolt -arrow B-.