Dismantling and assembling selector mechanism on gearbox from 09.98 — AUDI

Audi
Audi A3
1997
Power transmission
5-speed manual gearbox 02J
Edition
10.2007
Dismantling and assembling selector mechanism on gearbox from 09.98
Special tools and workshop equipment required
Thrust plate
VW 401
Press tool
VW 408 A
Tube
VW 423
Guide pin
VW 439
Thrust plate
VW 447 i
1
Internal puller
Kukko 21/3
Selector shaft
From gearbox build date 04 09 0, detent sleeve modified so that when shifting down from 5th gear to 4th gear the selector shaft is guided into the 4th gear selector gate
Fig.
From gearbox build date 06 08 01: additional detent spring in cover plate
Fig.
Check ring
Ball sleeve
Removing
Fig.
Pressing in
Fig.
Selector mechanism cover
Additional bolt fitted from gearbox build date 04 09 0 so that when shifting down from 5th gear to 4th gear the selector shaft is guided into the 4th gear selector gate
Fig.
Reversing light switch
F4
20 Nm
Lightly coat lug with MoS
2
grease
Cap
For gearbox breather
Relay lever
Installation position
Fig.
Bearing bush
Seal
Lever out with screwdriver
Installing
Fig.
Securing clip
Nut
20 Nm
Self-locking
Always renew
Gearbox selector lever
Install so that gap in splines aligns with selector shaft
Fig.
Can be renewed with selector mechanism installed
Installation position
Fig.
Cover plate
From gearbox date 06 08 01 with detent spring for selector shaft
Fig.
Removing ball sleeve from selector mechanism cover
Before pressing out ball sleeve, destroy plastic cage and remove balls.
A
Internal puller 18.5 ... 23.5 mm
, e.g.
Kukko 21/3
Pressing ball sleeve into selector mechanism cover
Installing oil seal (insert onto stop)
Installing gearbox selector lever
When installing gearbox selector lever, make sure that the gap in the splines
arrow A
aligns with the wider spline
arrow B
on the selector shaft.
Modified selector mechanism cover and selector shaft
From gearbox build date 04 09 0, bolt
2
is fitted in selector mechanism cover
1
.
Tightening torque
15 Nm
The detent sleeve on the selector shaft has been fitted with a ramp
3
for this purpose.
Function
When shifting down from 5th gear to 4th gear, bolt
2
guides the selector shaft by means of ramp
3
into 4th gear selector gate.
Selector shaft and cover plate modified
From gearbox build date 06 08 01 with recesses on selector shaft
A
.
Cover plate is fitted with spring
B
.
Function
The spring
B
in the cover plate engages into one of the recesses in the selector shaft
A
when a forward gear is engaged.