Dismantling and assembling selector forks: VW 1.8 (BBU)

02J
Special tools, workshop equipment, test and measuring appliances and auxiliary items required

VW 402 Thrust plate
3290/1 Thrust piece from fitting assembly 3290
3301 Assembly tool
VW 431 Press piece
VW 472/2 Spacer sleeve
10-206 Drift

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

80-200 Removal lever

10-508 Drift

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

2070 Tensioning device

Note:

It is not necessary to disassemble the selector fork group (item
7
) in order to disassembly and assemble selector segments, lock washers and angular contact ball bearings.

5th gear selector segment
Identification => fig.
1
.
After lock washer is installed, selector segment must still rotate freely.

Lock washer
Always renew.
Removing => fig.
2
.
Installing => fig.
3
.

5th gear selector fork
Adjusting => page
34-108
.

Bolt, 25 Nm
5th gear selector jaw

Angular contact ball bearing
Qty. 4
Removing => fig.
4
.
Pressing inner race into outer race => fig.
5
.
Installing => fig.
6
.

Selector fork group with selector plate
1st/2nd gear selector segment
Identification => fig.
1
.
After lock washer is installed, segment must still rotate freely.

3rd/4th gear selector segment
Identification => fig.
1
.
After lock washer is installed, segment must still rotate freely.

Sliding piece

Spring
Reversegear selector fork
Support for reverse gear selector fork
Retaining ring

Fig.1
Identifying selector segments

Dimension -a-

1 - 1st and 2nd gear selector segments = 12.1 mm

1st and 2nd gear selector segments in conjunction with revised synchromesh (=>page
35-50
) = 11.4 mm

The shorter selector segments can also be installed in older gearboxes

2 - 3rd and 4th gear selector segments = 7.7 mm

3 - 5th gear selector segments = 12.1 mm

Fig.2
Removing lock washer

Clamp selector fork in vice with jaw protectors -B-.
Lever lock washer -A- off in direction of arrow.

Fig.3
Installing lock washer

Press lock washer into groove of selector segment using socket and spinner handle.

Note:

After lock washer is installed, selector segment must still rotate freely.

A - Spinner handle with 10 mm socket

B - Vice jaw protectors

Fig.4
Removing angular contact ball bearing

Note:

When removing and installing angular contact ball bearing, do not bend selector forks.

Fig.5
Pressing inner race -A- of angular contact ball bearing into outer race

Inner race must engage in outer race.

Fig.6
Pulling angular contact ball bearing into selector fork onto limit stop

Depression in thrust piece 3290/1 faces ball bearing.

Fig.7
Selector fork with selector segments installed

Dim. -a- (mm)
1st/2nd gear selector fork · 87,2 ... 87,9
1st/2nd gear selector fork in conjunction with revised synchromesh (=>page ). 35-50 · 88,4 ... 89,1
3rd/4th gear selector fork · 96,0 ... 96,7

Selector segment allocation => Fig.
1
.