Shift Mechanism on Transmission Side, Disassembling and Assembling

Shift mechanism on transmission side, disassembling and assembling, 012/01W, 5 SPD. M/T

Special tools, testers and auxiliary items required:

^ Needle Bearing Drift VW 295
^ Adapter VW 295 A
^ Thrust Plate VW 401
^ Tube 28mm Dia. 210 mm VW 420
^ Sleeve VW 423
^ Spacer sleeve VW 472/2

Special tools, testers and auxiliary items required

Slide Hammer-Complete Set VW 771:

- 1 - Internal extractor Kukko 21/4:

Note:
^ Installed position of complete shift mechanism in transmission

1. Gear lock
^ For 5th and reverse gear

2. Torx bolt, 10 Nm
^ Black; for transmissions made out of aluminum only
^ Bright; for transmissions made out of aluminum or magnesium

3. O-ring
^ Always replace

4. Right stop bolt, 40 Nm
5. Seal
6. Relay shaft
7. Seal
8. Left stop bolt, 40 Nm

9. Shift detent
10. Torx bolt, 25 Nm
11. roll pin
12. Shift fork 5th and reverse gears
^ Installed position

13. Shift rod for 1st and 2nd gear as well as 5th and reverse gear
14. Ball sleeve
15. Shift fork for 1st and 2nd gear
16. Coupling plate
^ Installed position

17. Bearing bushing
18. Ball sleeve
^ Pry off shift rod using a screwdriver
^ Press onto shift rod

19. Shift rod for 3rd and 4th gear
20. Shift fork for 3rd and 4th gear
21. Roll pin
22. Cover
^ For selector shaft

23. Torx bolt, 20 Nm
24. Shift rod
25. Seal
^ Pry out using screwdriver
^ Insert with Tube 28mm Dia. 210 mm VW 420
^ Installed position

Installed position for 5th/reverse gear shift fork and coupling plate for shift rod.
Dimension - a - = 55 mm
Dimension - b - = 60 mm

Ball sleeve, removing and installing

Removing bushing for 3rd and 4th gear shift rod
A - Internal puller 22 to 28 mm, e.g. Kukko 21/4 with Slide Hammer-Complete Set VW 771

Driving in bushing for 3rd and 4th gear shift rod

Installed position of sealing washer
Dimension - a - = 1 mm

Installed position of complete selector mechanism in transmission
1. Shift fork 5th and reverse gears
2. Shift fork 3rd and 4th gears
3. Shift fork 1st and 2nd gears
4. Relay shaft
5. Shift detent
6. Shift rod