Shift Mechanism In Transmission, Disassembling and Assembling

Shift mechanism in transmission, disassembling and assembling





Special tools and workshop equipment required
^ VW 295 Drift
^ VW 295 A adapter
^ VW 401 Thrust plate
^ VW 420 Tube
^ VW 423 Tube
^ VW 472/2 Spacer sleeve

Special tools and workshop equipment required





^ VW 771 Multi-purpose tool





^ 1 - Kukko 21/4 Internal puller





Note: Installation position of complete shift mechanism in transmission

1 - Locking module for 5th gear and reverse gear
^ Removing and installing

2 - Torx bolt - 10 Nm
3 - O-ring
^ Always replace
4 - Right stop bolt - 40 Nm
5 - Washer
6 - Relay shaft
7 - Washer
8 - Left stop bolt - 40 Nm
9 - Detent segment
10 - Torx bolt - 25 Nm
11 - Spring pin
12 - 5th and reverse gear selector fork
^ Installation position
13 - Selector rods for 1st/2nd and 5th/reverse gear
14 - Ball sleeve
^ Removing and installing
15 - Selector fork, 1st and 2nd gear
16 - Relay lever
^ Installation position
17 - Mounting bushing for 3rd and 4th gear
^ Pulling out
^ Driving in
18 - Ball sleeve
^ Pry off the selector rod with a screwdriver
^ Press on the selector rod
19 - Selector rod for 3rd and 4th gear
20 - Selector fork, 3rd and 4th gear
21 - Spring pin
22 - Cover plate
^ For selector shaft
23 - Torx bolt - 20 Nm
24 - Selector shaft
25 - Sealing ring
^ Pry out with screwdriver
^ Insert using tube VW 420
^ Installation position

Fig. 1 Installation position of 5th and reverse gear selector fork and follower for selector rod:

^ Dimension a = 55 mm
^ Dimension a = 60 mm

Fig. 2 Removing and installing ball sleeve:

Fig. 3 Pulling out mounting bushing for 3rd and 4th gear selector rod:

A - Internal puller 22... 28 mm, e.g. Kukko 21/4, in conjunction with multipurpose tool VW 771

Fig. 4 Driving mounting bushing for 3rd and 4th gear selector rod home:

Fig. 5 Installation position of oil seal:

^ Fill space between sealing and dust lips with multi-purpose grease.
^ Lightly oil outer circumference of seal.
^ Insert oil seal using tube VW 420
^ Dimension a = 1 mm

Fig. 6 Installation position of complete shift mechanism in transmission:

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