Volkswagen Workshop Service and Repair Manuals

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

• ◆ VW 402 Thrust plate
• ◆ VW 408 A Press tool
• ◆ VW 431 Press piece
• ◆ VW 447 H Press plate
• ◆ VW 472/2 Spacer sleeve
• ◆ 10-206 Drift

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ 80-200 Lever

Notes:

• ◆ The selector plates and the selector forks are machined together (drilled). When renewing, renew complete selector mechanism.
• ◆ Do not confuse selector plate for 1/2 gear -item 10 - with selector plate for 3/4 gear -item 9 -.

• 3rd/4th gear selector fork
• Angular contact ball bearing
• ◆ Removing => Fig.1
• ◆ Pressing in => Fig.2
• Lock washer
• ◆ Always renew
• ◆ Removing => Fig.3
• ◆ Installing => Fig.4
• Circlip
• Washer

• Selector segment
• ◆ Identification => Fig.5
• ◆ After installing the lock washer, the segment should have no resistance to rotation
• Selector segment
• ◆ Identification => Fig.5
• ◆ After installing the lock washer, the segment should have no resistance to rotation
• 5th gear selector plate
• 3rd/4th gear selector plate
• 1st/2nd gear selector plate
• Reverse gear selector plate
• Pin
• Reverse gear selector fork
• Reverse gear mounting

• Circlip
• 1st/2nd selector fork
• Selector segment
• ◆ Identification => Fig.5
• ◆ After installing the lock washer, the segment should have no resistance to rotation
• 5th gear selector fork
• Selector segment
• ◆ Identification => Fig.5
• ◆ After installing the lock washer, the segment should have no resistance to rotation
• Fulcrum pin
• ◆ For 5th gear selector fork

→ Fig.1     Removing angular contact ball bearing

Note:

When removing and installing the inner races, do not bend selector forks.

→ Fig.2     Pressing in angular contact ball bearing onto stop

→ Fig.3     Removing lock washer

• ‒ Secure selector fork in vice with jaw protectors -B-.
• ‒ Lever off lock washer -A- in direction of arrow.

→ Fig.4     Installing lock washer

• ‒ Press lock washer into selector segment groove using socket and drive handle.

Note:

After lock washer is installed, selector segment must turn freely.

A - Socket driver, 10 mm A/F

B - Jaw protectors

→ Fig.5     Identifying selector segments

Dimension -a- in mm