Transmission Shift Mechanism, Disassembling and Assembling

Transmission shift mechanism, disassembling and assembling





Special tools and workshop equipment required
^ VW 295 Mandrel
^ VW 295 A Adapter
^ VW 401 Pressure plate
^ VW 420 Tubular section
^ VW 423 Tubular section
^ 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 shift mechanism assembly in transmission

1 - Locking unit 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 - Damping washer
6 - Guide shaft
7 - Damping 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 rod for 1st and 2nd gear and for
^ 5th and reverse gear
14 - Ball sleeve
^ Removing and installing
15 - 1st and 2nd gear selector fork
16 - Driver
^ Installation position
17 - Mounting bushing for 3rd and 4th gear
^ Extracting
^ Driving in
18 - Ball sleeve
^ Pry away from selector rod using a screwdriver
^ Press onto selector rod
19 - Selector rod for 3rd. and 4th gear
20 - 3rd and 4th gear selector fork
21 - Spring pin
22 - Cover
^ For selector shaft
23 - TORX bolt - 20 Nm
24 - Selector shaft
25 - Oil seal
^ Pry out with screwdriver Installation position

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

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

Fig. 2 Removing and installing ball sleeve:

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

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

Fig. 4 Drive in mounting bushing for 3rd and 4th gear selector rod as far as it will go:

Fig. 5 Installation position of oil seal:

- Half-fill space between sealing lip and dust lip with sealing grease G 052 128 A1.
- Slightly oil circumference of sealing ring.
- Insert oil seal with tubular section VW 420
^ Dimension a = 1 mm

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

1 - 5th and reverse gear selector fork
2 - 3rd and 4th gear selector fork
3 - 1st and 2nd gear selector fork
4 - Guide shaft
5 - Shifting catch
6 - Selector shaft