Dismantling and assembling selector forks: Gearbox codes GSE, GSG — VW

Dismantling and assembling selector forks: Gearbox codes FNT, FLU, GEQ, GAH, GEW=>Page
34-93
.

Special tools and workshop equipment required

VW 402 Thrust plate
3290/1 Press piece

3301 Assembly tool
VW 431 Press piece
VW 472/2 Spacer sleeve
10-206 Drift

Special tools and workshop equipment required

80-200 Removal lever

10-508 Drift

2070 Tensioning device

Note:

It is not necessary to disassemble the selector fork group page
34-106
item
1
in order to disassemble and assemble selector segments, lock washers and angular contact ball bearings.

Selector fork group with selector plate
3rd/4th gear selector segment
Marking page
34-108
Once the selector segment has been fitted it should be able to turn lightly.

Angular contact ball bearing
Qty. 4
remove page
34-109
Pressing inner race into outer race page
34-109
install page
34-110

Lock washer
Always renew.
remove page
34-110
install page
34-111

1st/2nd gear selector segment
Marking page
34-108
After lock washer is installed, segment must still rotate freely.

Selector fork 5th gear with selector segment
Selector segments are inseparably connected to the selector fork
Marking page
34-108

Mounting pin
For 5th gear bracket

Fig. 1
Identifying selector segments 5th gear with selector segment

Dimension -a-

1 - · Selector segment 1st and 2nd gear / · = · 10.2mm
2 - · Selector segment 3rd and 4th gear · = · 78.6mm
3 - · Selector fork 5th gear with selector segment · = · 79.5mm

Fig. 2
Selector fork 1st/2nd gear with selector segments

Dimension -a-=75mm

Fig. 3
Removing angular contact ball bearing

Note:

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

Fig.4
Pressing inner race -A- of angular contact ball bearing into outer race

Inner race must engage in outer race.

Fig.5
Pulling angular contact ball bearing into selector fork onto limit stop

Depression in thrust piece -3290/1- faces ball bearing.

Fig.6
Removing lock washer

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

Fig.7
Installing lock washer

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

Note:

Once the safety ring has been fitted the washer should be able to turn lightly.

A - Spinner handle with 10 mm socket

B - Vice jaw protectors