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- from assembly tool -3290-

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-   Note 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 -	5th gear selector segment

q	Identification → Fig.

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

2 -	Lock washer

q	Always renew

q	Removing → Fig.

q	Installing → Fig.

3 -	5th gear selector fork

q	Adjusting → Anchor

4 -	Bolt, 25 Nm

5 -	5th gear selector jaw

6 -	Angular contact ball bearing

q

Qty. 4

q	Removing → Fig.

q	Press inner race into outer race → Fig.

q	Installing → Fig.

7 -	Selector fork group with selector plate

8 -	1st/2nd gear selector segment

q	Identification → Fig.

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

9 -	Selector segment for 3rd and 4th gear

q	Identification → Fig.

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

10 -	Sliding piece

11 -

Spring

12 -	Selector fork for reverse gear

13 -	Support for reverse gear selector fork

14 -	Retaining ring

15 -

Identifying selector segments Dimension a -1- = 1st and 2nd gear selector segments = 12.1 mm 1st and 2nd gear selector segments in conjunction with modified synchronisation = 11.4 mm Shorter selector segments may also be installed in previous gearboxes. -2- = 3rd and 4th gear selector segments = 7.7 mm -3- = 5th gear selector segments = 12.1 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- Vice jaw protectors

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.

Selector fork with selector segments installed

	Dim. -a- (mm)
1st/2nd gear selector fork	87,2 ... 87,9
1st/2nd gear selector forks in conjunction with modified synchronisation	88,4 ... 89,1
3rd/4th gear selector fork	96,0 ... 96,7

Selector segment allocation → Fig..