Volkswagen Workshop Service and Repair Manuals

Selection forks - disassemble and assemble

Special tools and workshop equipment required

t	Plate -VW 402-

t	Pressure pin -VW 408A-

t	Pressure base -VW 431-

t	Pressure base -VW 447H-

t	Sleeve -VW 472/2-

t	Pin or VW 010-206 -10-206-

t  Ejector lever -80-200-   Note To remove or install the selector segments (skids), circlips and ball bearings, you are not required to remove the change rail set.

1 -	Change rail set with selector forks

2 -	Selector segment 3rd/4th gear

q	Identification → Fig.

q	After assembling, it shall move freely

q	Individual selector segments are mounted in some transmissions → Fig.

q	Identification of individual segments → Fig.

3 -	Ball bearing

q

4 units

q	Removal → Fig..

q	Installation → Fig.

4 -

Circlip

q	Always replace

q	Removal → Fig..

q	Installation → Fig.

5 -	Selector segment 1st/2nd gear

q	Identification → Fig.

q	After assembling, it shall move freely

6 -	5th gear selector fork with selector segment

q	The selector segments should not be removed from the selector fork

q	Identification → Fig.

7 -	Bearing pin

q	For the selector fork for 5th gear

Identification of the selector segments in the 5th gear selector fork, including the selector segments for 1st/2nd and 3rd/4th gears Dimension -a-: 1 -  Selector segment 1st/2nd gear = 10.2 mm 2 -  Selector segment 3rd/4th gear = 78.6 mm 3 -  Selector fork for 5th gear, including the selector segments = 79.5 mm

Selector fork for 1st/2nd gear, including the selector segments Dimension -a- = 75 mm

Individual selector segments for 3rd/4th gear -A- After assembling the gear selector segments, they shall move freely.   Note Only some transmissions have these individual segments.

Identification of the individual selector segments for 3rd/4th gear Dimension -a-: 1 -  Short selector segment 3rd/4th gear = 10.2 mm 2 -  Long selector segment 3rd/4th gear = 10.2 mm   Note When removing or installing internal tracks, do not twist the selection forks.

Removing ball bearing   Note When removing or installing internal tracks, do not twist the selection forks.

Installing ball bearing

Removing circlip –  Fasten the selection forks to the vise with jaw -B-. –  Remove circlip -A- by leveraging towards -arrow-.

Installing circlip A -  Barrel wrench 10 B -  Jaw –  Press the circlip on the fork segment groove by using a barrel wrench.   Note After installing the circlip, the fork segment shall move freely.