Disassembling and Assembling
Selector mechanism, disassembling and assembling
1. 5th/Reverse gear detent
^ Removing, installing and checking
2. Torx(R) screw
^ 10 Nm (7 ft. lbs.)
3. O-ring
^ Always replace
4. Right stop bolt
^ 40 Nm (30 ft. lbs.)
5. Oil seal
6. Relay shaft
7. Oil seal
8. Left stop bolt
^ 40 Nm (30 ft. lbs.)
9. Shift detent
10. Torx(R) bolt
^ 25 Nm (18 ft. lbs.)
11. Spring pin
12. 5th and reverse gear selector fork
^ Installation position; see Fig. 1
13. 1st gearl2nd gear, 5th and reverse gear shift rod
14. Ball sleeve
^ Removing and installing; see Fig. 2
15. 1st and 2nd gear selector fork
16. Shift yoke
^ Installation position; see Fig. 1
17. Bushing
^ Removing; see Fig. 3
^ Installing; see Fig. 4
18. Ball sleeve
^ Pry off the selector shaft with a screwdriver
^ Press onto the selector shaft
19. 3rd and 4th gear selector shaft
20. 3rd and 4th gear selector fork
21. Spring pin
22. Shift rod cover
23. Torx(R) screw
^ 20 Nm (15 ft. lbs.)
24. Shift rod
25. oil seal
^ Pry out with screwdriver
^ Installation position; see Fig. 5
Note: Installation position of the complete selector mechanism in transmission Fig. 6
Fig. 1 Installation position of 5th and reverse gear selector fork and shift rod yoke.
Dimension a = 55 mm (2.16 inch)
Dimension b = 60 mm (2.36 inch)
Fig. 2 Removing and installing ball sleeve
Fig. 3 Pulling out mounting bushing for 3rd and 4th gear selector shaft
A -Internal extractor 22 - 28 mm, e g Kukko 21/4 and VW 771
Fig. 4 Driving in 3rd and 4th gear selector shaft mounting bushing onto stop
Fig. 5 Oil seal installation position
Dimension a = 1 mm (0.039 inch)
Fig. 6 Installation position of complete selector mechanism in transmission:
1. 5th and reverse gear selector fork
2. 3rd and 4th gear selector fork
3. 1st and 2nd gear selector fork
4. Relay shaft
5. Shift detent
6. Shift rod
Checking and replacing 5th and reverse gear detent
- Remove cover plate (arrow -2-) above right-hand axle shaft.
- Press down cover plate (arrow-1-) above right-hand axle shaft.
- Remove 5th and reverse gear detent (arrow).
Checking and assembling the 5th and reverse gear detent:
- Position spring -1- into housing -2- and apply slight pressure; rotate counterclockwise until spring engages in base of housing.
- Insert bushing -3- onto spring so that bent end of spring locates in groove.
- Push bushing -3- against spring and turn approx. 1 turn counterclockwise until tab on bushing aligns with groove in housing -2-.
- Press tab on bushing -3- onto stop in groove in housing -2-.
- Turn bushing -3- clockwise and release; bushing -3- will spring into final installed position.
Installed position:
The tab (arrow -A-) on the bushing must always be opposite the groove in the housing (arrow-B-).
Installation position of complete 5th and reverse gear detent in transmission:
The recess (arrow-A-) faces bolt (arrow-B-)