Shift Forks, Disassembling and Assembling
Shift Forks, Disassembling and Assembling
Special tools, testers and auxiliary items required
• Pressure plate (VW 402)
• Thrust piece (3290/1)
• Alignment fixture (3301)
• Thrust piece (VW 431)
• Spacer sleeve (VW 472/2)
• Drift (10 - 206)
• Pry lever (80-200)
• Assembly drift (10 - 508)
• Tensioning device (2070)
• The shift fork group (--> [ 7 Shift fork group and shift rails ]) does not need to be disassembled to remove and install shift segments, lock washers and angular contact ball bearings.
1 5th gear shift segment
• Identification --> [ Identification of shift segments ]
• After installing lock washer the shift segment must still rotate freely
2 Lock washer
• Always replace
• Removing --> [ Removing lock washer ]
• Installing --> [ Installing lock washer ]
3 5th gear shift fork
• Adjusting
4 Bolt, 25 Nm
5 5th gear shift jaw
6 Angular contact ball bearing
• Quantity: 4
• Removing --> [ Removing angular contact ball bearing ]
• Pressing inner race into outer race --> [ Pressing angular contact ball bearing inner race into outer race ]
• Installing --> [ Pulling angular contact ball bearing into shift fork up to limit stop ]
7 Shift fork group and shift rails
8 1st/2nd gear shift segment
• Identification --> [ Identification of shift segments ]
• After installing lock washer the segment must still rotate freely
9 3rd/4th gear shift segment
• Identification --> [ Identification of shift segments ]
• After installing lock washer the segment must still rotate freely
10 Sliding piece
11 Spring
12 Reverse gear shift fork
13 Support for reverse gear shift fork
14 Securing ring
Identification of shift segments
Dimension - a -
1 1st and 2nd gear shift segments = 11.4 mm
2 3rd and 4th gear shift segments = 7.7 mm
3 5th gear shift segments = 12.1 mm
Removing lock washer
- Secure shift fork in vise with protective jaws - B -.
- Pry off lock washer - A - in direction of - arrow -.
Installing lock washer
- Press lock washer into shift segment groove using socket and drive handle.
• After installing lock washer the shift segment must still rotate freely.
A Socket driver, 10 mm
B Protective jaws
Removing angular contact ball bearing
• When removing and installing angular contact ball bearing, do not bend shift forks.
Pressing angular contact ball bearing inner race - A - into outer race
The inner race must engage with outer race.
Pulling angular contact ball bearing into shift fork up to limit stop
The recess in press piece (3290/1) faces toward the ball bearing.
Shift fork with shift segments installed
Allocation of shift segments --> [ Identification of shift segments ]