Shift Fork: Service and Repair

5 Speed Manual 02J

Selector Forks, Disassembling and Assembling

Special tools






- VW 402 Press plate
- VW 408 A Punch
- VW 431 Thrust pad
- 447 H Press Plate
- VW 472/2 Spacer sleeve
- 10-206 Drift






1 Selector segment
- Identification refer to Fig. 1
- After installing circlip segment must rotate freely
2 Circlip
- Pry off with screwdriver
- Installing refer to Fig. 2
- Always replace
3 5th gear selector fork
- Adjusting
4 5th gear selector jaw
5 Bolt
- 25 Nm (18 ft. lbs.)
6 5th gear selector rail
7 Circlip
8 Washer
9 3rd/4th gear selector rail
10 1st/2nd gear selector rail
11 Reverse gear selector rail
12 3rd/4th gear selector fork
- With selector segments refer to Fig. 5
13 Selector segment
- Identification refer to Fig. 1
- After installing circlip segment must rotate freely
14 Bearing
15 Bearing inner race
- Removing refer to Fig. 3
- Pressing in refer to Fig. 4
16 1st/2nd selector fork
- With selector segments refer to Fig. 5
17 Selector segment
- Identification refer to Fig. 1
- After installing circlip segment must rotate freely
18 Circlip
19 Support for reverse gear selector fork
20 Reverse gear selector fork
21 Spring
22 Domed sliding piece

Fig. 1 Identifying selector segments






Dimension -a-
1 1st and 2nd gear selector segments 12.1 mm
2 3rd and 4th gear selector segments 77 mm
3 5th gear selector segments = 12.1 mm

Fig. 2 Installing circlip






- Press circlip into selector segment groove with socket.

Note:
After installing the circlip the selector segment must rotate freely

A Socket driver, 10 mm
B Vise clamps

Fig. 3 Removing bearing inner race






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

Fig. 4 Pressing inner race in onto stop






Fig. 5 Selector fork with selector segments installed