Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ VW 439 Guide pin
• ◆ VW 401 Thrust plate
• ◆ VW 408 A Press tool
• ◆ VW 447 i Thrust plate
• ◆ 3129 Fitting tool

Special tools and workshop equipment required

• ◆ 1 - Internal puller Kukko 21/3

• Selector shaft
• ◆ Revised stop sleeves, which allows the selector shaft to be guided into the 4th gear gate when changing down from 5th to 4th gear, have been introduced as of gearbox build date 04 09 0 =>Fig.4
• ◆ From gearbox build date 06 08 1 additional locking mechanism in end cover =>Fig.5
• Stop ring
• Ball sleeve
• ◆ Removing => Fig.1
• ◆ Pressing in => Fig.2
• Selector mechanism cover
• ◆ With an additional bolt which allows the selector shaft to be guided into the 4th gear gate when changing down from 5th to 4th gear, have been introduced as of gearbox build date 04 09 0 => Fig.4

• Reversing light switch, 20 Nm
• ◆ Lightly coat lug with MoS2 grease
• Cap
• ◆ For gearbox breather
• Relay lever
• ◆ Installation position
• Bush
• Oil seal
• ◆ Lever out with screwdriver
• ◆ Installing => Fig. 3
• Circlip
• Hexagon nut, 20 Nm
• ◆ Self-locking
• ◆ Always renew

• Gear selector lever
• ◆ Install so that the master spline aligns with selector shaft
• ◆ Can be replaced with the selector mechanism installed
• ◆ Installation position => Page 34-44
• End cover
• ◆ From gearbox build date 06 08 1 with locking mechanism for the selector shaft => Fig.5

→ Fig.1     Removing ball sleeve from selector mechanism cover

• ‒ Before pulling out ball sleeve, destroy plastic cage and remove balls.

A - Internal extractor, e.g. Kukko 21/3, 18.5 ... 23.5 mm

→ Fig.2     Knocking ball sleeve into selector mechanism cover

→ Fig.3     Installing oil seal onto stop

→ Fig.4     Revised selector cover and selector shaft

As of gearbox build date 04 09 0 bolt -2- is installed in selector cover -1-.

Tightening torque

15 Nm

In conjunction with this the stop sleeve is fitted with a bridge -3-.

Functional check

When shifting down from 5th gear to 4th gear the bolt -2- guides the selector shaft over bridge -3- into 4th gear gate.

→ Fig.5     Revised selector shaft and selector cover

From gearbox build date 06 08 1 the selector shaft is equipped with four grooves -A-.

The spring clip -B- is inserted in the cover.

Functional check

Selector shaft is locked into cover by inserting a spring clip -B- through one of the grooves -A-, with a forward gear engaged.