Transmission Selector Mechanism, Disassembling and Assembling

Transmission selector mechanism from 05.99, disassembling and assembling, 02J, 5 Spd. M/T

Special tools and equipment:

^ VW 439 Guide pin
^ VW 401 Thrust plate
^ VW 408 A Press tool
^ VW 447 i Thrust plate
^ 3129 Installation tool

Special tools and equipment

1 - Internal puller Kukko 21/3:

1 - Selector shaft
^ Revised stop sleeves, which allow the selector shaft to be guided into the 4th gear gate when changing down from 5th to 4th gear, have been introduced as of transmission build date 04 09 0 go to Fig. 4
^ As of transmission build date 06 08 1 additional locking mechanism in end cover go to Fig. 5

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

4 - Selector mechanism cover
^ With an additional bolt which allows the selector shaft to be guided into the 4th gear gate when changing down from 5th to 4th gear, introduced as of transmission build date 04 09 0 go to Fig. 4

5 - Reverse light switch, 20 Nm
^ Lightly coat lug with MoS2 grease

6 - Cap
^ For transmission breather

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

10 - Circlip
11 - Hex nut, 20 Nm
^ Self-locking
^ Always replace

12 - Gear selector lever
^ Install so that the master spline aligns with selector shaft
^ Can be replaced with the selector mechanism installed

13 - End cover
^ As of transmission build date 06 08 1 with locking mechanism for selector shaft





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 Driving ball sleeve into selector mechanism cover





Fig. 3 Installing oil seal onto stop





Fig. 4 Revised selector cover and selector shaft As of transmission build date 04 09 0 bolt -2- is installed in selector cover -1-.

Tightening torque

15 Nm
In conjunction with this the stop sleeve is fitted with a bridge -3-.

Functional check
When shifting down from 5th gear to 4th gear the bolt -2- guides the selector shaft over bridge -3- into 4th gear gate.





Fig. 5 Revised selector shaft and selector cover
As of transmission build date 06 08 1 the selector shaft is equipped with four grooves -A-.

The spring clip -B- is inserted in the cover.

Functional check
The selector shaft is locked into the cover by inserting the spring clip -B- through one of the grooves -A-, with a forward gear engaged.