Dismantling and assembling gear selector mechanism in gearbox — AUDI

01AA
Note:

Installation position of the complete selector mechanism in gearbox => Fig.
6

Locking unit for 5th gear and reverse gear
Removing and installing=>Page
34-105

TORX-bolt - 10 Nm
O-ring
Replacing

Right stop bolt - 40 Nm
Insulation

Relay shaft
Insulation
Left stop bolt - 40 Nm
Detent segment
TORX-bolt - 25 Nm
Spring pin
5th and reverse gear selector fork
Installation position => Fig.
1
.

Selector rods for 1st/2nd and 5th/reverse gear
Ball sleeve
Removing and installing =>Fig.
2

Selector fork, 1st and 2nd gear
Actuating arm
Installation position => Fig.
1
.

Bush
Pulling out =>Fig.
3
Driving in =>Fig.
4

Ball sleeve
Lever off the selector rod with a screwdriver
Press onto the selector rod

Selector rod for 3rd and 4th gear
Selector fork, 3rd and 4th gear
Spring pin
Cap
For selector shaft

TORX-bolt - 20 Nm
Selector shaft
Sealing ring
Lever out with screwdriver
Installation position => Fig.
5
.
Pack sealing ring between sealing and dust lips half-full with sealing grease G 052 128 A1.

Fig.1
Installation position of 5th and reverse gear selector fork and actuating arm for selector rod

Dimension a = 55 mm
Dimension 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 multi-purpose tool VW 771

Fig.4
Driving mounting bush for 3rd and 4th gear selector rod home

Fig.5
Oil seal installation position

Lightly oil outer circumference of sealing ring.
Pack space between sealing and dust lips with sealing grease G 052 128 A1.
Insert sealing ring with tube VW 420.
Dimension a = 1 mm

Fig.6
Installation position of complete selector mechanism in gearbox

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-hand drive shaft.
Detach heat shield -arrow 1- above right-hand drive shaft and pivot downwards.

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- into the spring so that the bent end of the spring locates in the designated 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 installation 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 gearbox:

The recess (arrow -A-) faces bolt (arrow-B-).