Selector Mechanism on Transmission Side, As of 06.99, Disassembling and Assembling

Selector mechanism on transmission side, as of 06.99, disassembling and assembling, 02J, 5 Spd. M/T

Special tools and equipment:

- VW 401 Press plate
- VW 408 A Press tool
- VW 423 Tube
- VW 439 Guide pin
- VW 447 I Thrust plate
1. Kukko 21/3 Internal puller





1. Selector shaft
^ As of date of manufacture September 4th 2000 the locating sleeve has been changed in order to guide the switching gear into the 4th gear gap when shifting down from 5th to 4th gear go to Fig. 4

2. Stop ring
3. Ball sleeve
^ Removing go to Fig. 1
^ Pressing in go to Fig. 2

4. Selector mechanism cover
^ As of date of manufacture of September 4th 2000, with additional bolt in order to guide the switching gear into the 4th gear gap when shifting down from 5th to 4th gear go to Fig. 4

5. Reversing light switch, 20 Nm
^ Lightly coat lug with MoS2 grease

6. Cap
^ For transmission breather

7. Relay lever
^ Installation position

8. Bushing
9. Oil seal
^ Pry out with screwdriver
^ Installing go to Fig. 3

10. Circlip
11. Hex nut, 25 Nm
^ Self-locking
^ Always replace

12. Gear selector lever
^ Install so that master spline aligns with selector shaft
^ Can be replaced with selector mechanism installed
^ Installation position

13. End cover





Fig. 1 Removing ball sleeve from selector mechanism cover
- Before pulling out ball sleeve, destroy plastic cage and remove balls.
- A - Internal extractor, e.g. Kukko 21/3, 18.5... 23.5 mm





Fig. 2 Pressing ball sleeve into selector mechanism cover





Fig. 3 Installing oil seal onto stop





Fig. 4 Selector mechanism cover and selector shaft changed
As of date of manufacture of September 4th 2000 the bolt -2- is installed into the selector mechanism cover -1-.

Tightening torque 15 Nm
The selector shaft locating sleeve has been equipped with the segment -3-.

Function
When shifting down from the 5th to 4th gear the bolt -2- guides the selector shaft via the segment -3- into the 4th gear gap.





Fig. 5 Selector mechanism cover and selector shaft changed
- As of date of manufacture of August 6th 2001 the selector shaft is manufactured with the recesses -A-.
- The spring -B- is fitted in the selector mechanism cover.

Function
With one selected forward gear, the selector shaft is secured via one of the recesses -A- with the spring -B- in the selector mechanism cover.