Overhaul

Transmission selector mechanism, disassembling and assembling
Special tools and equipment
^ VW295 needle bearing drift
^ VW295A needle-bearing drift
^ VW401 thrust plate
^ VW 423 sleeve
^ VW472/2 spacer sleeve
^ VW771 slide hammer- complete set
^ Kukko 21/1 extractor

Note: Installation position of the complete selector mechanism in transmission see Fig. 6.





1. Locking unit for 5th gear and reverse gear
^ Removing and installing
2. Torx bolt, 10 Nm
3. O-ring
^ Replace
4. Right stop bolt, 40 Nm
5. Oil seal
6. Relay shaft
7. Oil seal
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 see Fig. 1
13. Selector rod for 1st and 2nd gear as well as for 5th and reverse gear
14. Ball sleeve
^ Removing and installing see Fig. 2
15. Selector fork for 1st and 2nd gear
16. Coupling plate
^ Installation position see Fig. 1
17. Bush
^ Removing see Fig. 3
^ Installing see Fig. 4
18. Ball sleeve
^ Lever off the selector rod with a screwdriver
^ Press onto the selector rod
19. Selector rod for 3rd and 4th gear
20. Selector fork for 3rd and 4th gear
21. Spring pin
22. Cover
^ For selector shaft
23. Torx bolt, 20 Nm
24. Selector shaft
25. Oil seal
^ Lever out with screwdriver
^ Installation position see Fig. 5





Fig. 1 Installation position of 5th and reverse gear selector fork and coupling plate for selector rod
^ Distance -a- = 55 mm
^ Distance -b- = 60 mm





Fig. 2 Removing and installing ball sleeve





Fig. 3 Pulling out mounting bush for 3rd and 4th gear selector rod
A - Internal puller 22-28 mm, e.g. Kukko 21/4, in conjunction with multipurpose tool VW 771





Fig. 4 Driving in 3rd and 4th gear selector rod mounting bush onto stop





Fig. 5 Oil seal installation position
- Fill space between sealing and dust lips with multi-purpose grease.
- Lightly oil outer circumference of seal.
^ Distance -a- = 1 mm





Fig. 6 Installation position of complete selector mechanism in transmission
1. Selector fork for 5th gear and reverse gear
2. Selector fork for 3rd gear and 4th gear
3. Selector fork for 1st gear and 2nd gear
4. Relay shaft
5. Detent mechanism
6. Selector shaft

Removing and installing locking unit for 5th gear and reverse gear





- Remove heat shield -arrow-2- above right axle shaft.
- Detach heat shield -arrow -1- above right axle shaft and pivot downward.





- Remove locking unit -arrow-.

Assembling locking unit:





- Insert spring -1- into housing -2- and, while exerting light pressure, turn spring to the left until it locates in the base of the housing.
- Insert bush -3- onto the spring so that the bent end of the spring locates in the groove.
- Push bush against spring and turn approx. One turn to left, until the lug on the bush aligns with the groove in the housing.
- Press lug on bush onto stop in the groove in the housing.
- Turn bush to right and release.
The bush will jump into the correct position.





Installation position of bush.
- The lug (arrow -A-) on the bush must always be opposite the groove in the housing (arrow -B-).
Checking installation position:
- Turn bush to left and release.
The bush should spring back into position; the lug must be against the stop (direction indicated by arrow -A-).





Installation position of complete locking unit in transmission:
The recess (arrow-A-) faces bolt (arrow -B-).