Disassembling and Assembling

5 Speed Manual 02J

Selector forks, disassembling and assembling





Special tools and equipment
- 10-206 Drift
- VW 431 Press piece
- VW 402 Thrust plate
- VW 408 A Press tool
- VW 472/2 Spacer sleeve





1. Selector segment
- Identification refer to Fig. 1
- After installing the circlip the selector segment must rotate freely
2. Circlip
- Pry off with screwdriver
- Installing refer to Fig. 2
- Always replace
3. 5th gear selector fork
- Adjusting.
4. 5th gear selector jaw
5. Bolt, 25 Nm
6. 5th gear selector plate
7. Circlip
8. Washer
9. 3rd/4th gear selector plate
10. 1st/2nd gear selector plate
11. Reverse gear selector plate
12. 3rd/4th gear selector fork
- With selector segments refer to Fig. 5
13. Selector segment
- Identification refer to Fig. 1
- After installing the circlip the segment must rotate freely
14. Bearing
15. Bearing inner race,
- Removing Fig. 3
- Pressing in Fig. 4
16. 1st/2nd selector fork
- With selector segments refer to Fig. 5
17. Selector segment
- Identification refer to Fig. 1
- After installing the circlip the segment must rotate freely
18. Circlip
19. Support for reverse gear selector fork
20. Reverse gear selector fork
21. Spring
22. Domed sliding piece





Fig. 1 Identifying selector segments
Dimension -a-
1. 1st and 2nd gear selector segments = 12.1 mm
2. 3rd and 4th gear selector segments = 7.7 mm
3. 5th gear selector segments = 12.1 mm





Fig.2 Installing circlip
- Press circlip into selector segment groove with socket.

Note: After installing the circlip the selector segment must rotate freely.
A - Socket driver, 10 mm
B - Jaw protectors





Fig. 3 Removing bearing inner race

Note: When removing and installing the inner races do not bend selector forks.





Fig. 4 Pressing inner race in onto stop





Fig. 5 Selector fork with selector segments installed
Selector segment assignment refer to Fig. 1.