Dismantling and assembling gearbox selector mechanism — VW

Special tools and workshop equipment required

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

Selector shaft
Revised stop sleeves, which allows the selector shaft to be guided into the 4th gear gate when changing down from 5th to 4th gear, have been introduced as of gearbox build date 04 09 0 =>Fig.
4
From gearbox build date 06 08 1 additional locking mechanism in end cover =>Fig.
5

Stop ring
Ball sleeve
Removing => Fig.
1
Pressing in => Fig.
2

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, have been introduced as of gearbox build date 04 09 0 => Fig.
4

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

Cap
For gearbox breather

Relay lever
Installation position => Page
34-13

Bush
Oil seal
Lever out with screwdriver
Installing => Fig.
3

Circlip
Hexagon nut, 25 Nm
Self-locking
Always renew

Gear selector lever
Install so that the master spline aligns with selector shaft
Can be replaced with the selector mechanism installed
Installation position =>Page
34-13

End cover
From gearbox build date 06 08 1 with locking mechanism for the selector shaft => Fig.
5

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
Revised selector cover and selector shaft

As of gearbox 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

From gearbox 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

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