Shift Forks
Shift Forks
Special tools, testers and auxiliary items required
• Thrust Plate (VW 402)
• Subframe Support Assm. Device (329o)
• Thrust Pad 16.5/28 mm Dia. (VW 431)
• Assembly Tool (3301)
• Sleeve (VW 472/2)
• Drift (10 - 206)
• Assembly Mandrel (10 - 508)
• Pry Lever - Rmv Outside Mirror (80-200)
• Spring Strut Compressor (2070)
• The shift fork group (- item 1 -) does not need to be disassembled to remove and install shift segments, lock washers and angular contact ball bearings.
1 - Selector Fork with Rails
2 - 3rd/4th Gear Shift Segment
• Identification.
• The shift segment must still rotate easily after assembly.
3 - Angular Contact Ball Bearing
• Quantity: 4
• Removing.
• Pressing the bearing inner race into the outer race.
• Installing.
4 - Lock Washer
• Always replace.
• Removing.
• Installing.
5 - 1st/2nd Gear Shift Segment
• Identification.
• The shift segment must still rotate easily after the lock washer is installed.
• Shift fork with shift segment
6 - 5th Gear Shift Fork with Shift Segments
• Shift segments are connected to shift fork and cannot be separated.
• Identification.
7 - Pin
• For the 5th gear shift fork.
Identification of Shift Segments and 5th Gear Shift Fork with Shift Segments
Dimension - a -
1. 1st/2nd gear shift segments = 10.2 mm
2. 3rd/4th gear shift segment = 78.6 mm
3. 5th gear shift fork with shift segments = 79.5 mm
1st/2nd Gear Shift Fork with Shift Segments
- a - = 75 mm
Removing the Lock Washer
- Secure the shift fork in a vise with protective jaws - B -.
- Pry off the lock washer - A - in the - direction of the arrow -.
Installing the Lock Washer
- Press the lock washer in the groove in the shift segment using a socket wrench
• The shift segment must still rotate easily after the lock washer is installed.
A 10 mm socket wrench
B Protective jaws
Removing the Angular Contact Ball Bearing
• Be careful not to bend the shift forks when removing and installing the angular contact ball bearing.
Installing the Angular Contact Ball Bearing Inner Race - A - into the Outer Race
The bearing inner race must engage with the outer race.
Installing the Angular Contact Ball Bearing into the Shift Fork
The depression inside the (3290/1) faces the ball bearing.