Location and bearings of gearshift shaft in gearbox modified — VW

From gearbox date 03 01 9 the location and bearings of the gearshift shaft were modified:

Location of gearshift shaft
Formerly: The gearshift shaft 1 was located by a ball detent.

NEW:

The gearshift shaft 1 is located by the locating screw 2 via the detent element 3.

The locating screw is installed instead of the previous dog point screw. The threaded hole in the gearbox housing has been altered to suit the larger thread diameter of the locating screw.

Tightening torque : 20 Nm

Note:

Before fitting the locating screw, two threads should be coated with sealing compound AMV 188 200 03.

Bearings of gearshift shaft

Formerly: Bushes

New:

Ball sleeve bearing. The gearshift shaft is mounted in the end cover 4 and in the gearbox housing in the ball sleeves 5 and 6.

Removing and installing the ball sleeve 5 - fig. 1 and 2
Removing and installing the ball sleeve 6 - fig. 3 and 4
Fitting position - fig. 4

The oil deflector plate 7 and the spring 8 have been altered to suit the modified bearings of the gearshift shaft in the end cover. Location Fig.5 and 6

The oil seal 9 has also been matched to the modified bearings of the gearshift shaft in the gearbox housing. Location Fig.7

Removal: Lever out with release lever 681.

Installing: Fig.8

Note:

The modified "inner shifting" cannot be installed in previous gearbox housings.

Fig.1
Removing ball sleeve from end cover

A = Support , e.g. Kukko 22/1

B = Extractor 14-19 mm e. g. Kukko 21/2

Fig.2
Installing ball sleeve in end cover

Drive in until tool makes contact.

Fig.3
Pulling ball sleeve out or gearbox housing

A = Extractor 18-23 mm e.g. Kukko 21/3

B = Support, e.g. Kukko 22/1

Fig.4
Pulling ball sleeve into gearbox housing

Pull in to stop -arrow 1-.

Fitting position:

On the oil seal side the ball sleeve projects out of the bore -arrow 2-.

Fig.5
Oil deflector plate difference

Oil deflector plate up to Assembly
date 22 01 9
Dimension a = 25 mm.

Oil deflector plate from Assembly
date 23 01 9
Dimension a = 31 mm.

Fig.6
Spring difference

Spring up to Assembly date 22 01 9
Dimension a = 23.5 mm.

Spring from Assembly date 23 01 9
Dimension a = 29.3 mm

Fig.7
Oil seal difference

1 - Oil seal up to Assembly date
22 01 9
Dimension a = 6 mm.

2 - Oil seal from Assembly date
23 01 9
Dimension a = 4.5mm.

Note:

The new oil seal has a shoulder on the inner diameter -arrow-.

Fig.8
Installing new oil seal in the gearbox housing

Pull in to stop.
With gearbox out, knock in with VW 521/5
With gearbox installed, pull in as shown.