Selector Forks, Disassembling and Assembling

Selector forks, disassembling and assembling, 02J, 5 Spd. M/T

Special tools and equipment:

- VW 402 Press plate
- 3290/1 Press piece from mounting device 3290
- 3301 Mounting device
- VW 431 Press piece
- VW 472/2 Spacer sleeve
- 10-206 Drift

Special tools and equipment
- 80-200 Removal lever
- 10-508 Assembly mandrel

Special tools and equipment
- 2070 Tensioning device

Note: The selector fork group (item 7) does not need disassembling and assembling the selector segments to disassemble the bearings and the circlips.





1. Selector segment 5th gear
^ Identification go to Fig. 1
^ After installing circlip selector segment must rotate freely

2. Circlip
^ Always replace
^ Removing go to Fig. 3
^ Installing go to Fig. 3

3. 5th gear selector fork
4. Bolt, 25 Nm
5. 5th gear selector jaw
6. Bearing
^ 4 Pieces
^ Removing go to Fig. 4
^ Pressing inner ring into outer ring go to Fig. 5
^ Pressing in go to Fig. 6

7. Selector fork group with selector rails
8. Selector segment 1st/2nd gear
^ Identification go to Fig. 1
^ After installing the circlip the segment must rotate freely

9. Selector segment 3rd/4th gear
^ Identification go to Fig. 1
^ After installing the circlip the segment must rotate freely

10. Domed sliding piece
11. Spring
12. Reverse gear selector fork
13. Support for reverse gear selector fork
14. Circlip





Fig. 1 Identifying selector segments

Dimension -a-
1 - 1st and 2nd gear selector segments = 12.1 mm
1st and 2nd gear selector segments with changed synchronization = 11.4 mm
The shorter selector segments can be installed in previous transmissions.
2 - 3rd and 4th gear selector segments = 7.7 mm
3 - 5th gear selector segments = 12.1 mm





Fig. 2 Removing circlip
- Tighten selector fork into screwed stick with the vice clamps -B-.
- Pry circlip in direction of arrow -A-.





Fig. 3 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 A/F
B - Vice clamps





Fig. 4 Removing bearing inner race

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





Fig. 5 Pressing bearing inner ring -A- into outer ring
The inner ring must secure with the outer ring.





Fig. 6 Pressing inner race in the selector fork onto stop
The hollow in press piece 3290/1 points to bearing.





Fig. 7 Selector fork with selector segments installed





Selector segment assignment go to Fig. 1.