Disassembling and Assembling

5 Speed Manual 02J

Transmission selector mechanism, disassembling and assembling





Special tools and equipment
- VW 439 Guide pin
- VW 401 Thrust plate
- VW 408 A Press tool
- VW 447 i Thrust plate
- 3129 Fitting tool

Special tools and equipment





1 - Internal puller Kukko 21/3





1. Selector shaft
- Revised stop sleeves, which allow the selector shaft to be guided into the 4th gear gate when changing down from 5th to 4th gear, have been introduced as of transmission build date 04 090 Refer to Fig.4
2. Stop ring
3. Ball sleeve
- Removing Refer to Fig. 1
- Pressing in Refer to Fig. 2
4. Selector mechanism cover
- With an additional bolt which allows the selector shaft to be guided into the 4th gear gate when changing down from 5th to 4th gear, have been introduced as of transmission build date 04 09 0 Refer to Fig. 4
5. Reverse light switch, 20 Nm
- Lightly coat lug with MoS2 grease
6. Cap
- For transmission breather
7. Relay lever
- Installation position
8. Bushing
9. Oil seal
- Pry out with screwdriver
- Installing Refer to Fig. 3
10. Circlip
11. Hex nut, 20 Nm
- Self-locking
- Always replace
12. Gear selector lever
- Install so that the master spline aligns with selector shaft
- Can be replaced with the selector mechanism installed
- Installation position
13. End cover





Fig. 1 Removing ball sleeve from selector mechanism cover
- Before pulling out ball sleeve, destroy plastic cage and remove balls.
A - Internal extractor, e.g. Kukko 21/3, 18.5 ... 23.5 mm





Fig. 2 Driving ball sleeve into selector mechanism cover





Fig. 3 Installing oil seal onto stop





Fig. 4 Revised selector cover and selector shaft
As of transmission build date 04 09 0 bolt -2- is installed in selector cover -1-.
Tightening torque 15 Nm
In conjunction with this the stop sleeve is fitted with a bridge -3-.
Functional check
When shifting down from 5th gear to 4th gear the bolt -2- guides the selector shaft over bridge -3- into 4th gear gate.