Changing gear selector rod seal and bush

[hayesey]

you will need:

3.1 litres of gearbox oil : G 060726A2 (Approx £4 per litre)
Seal: No 085301227 (Approx £4)
Bush: No 001301209 (Aprrox £4)
A length of pipe about 100mm in length and and wide enough to go over the selector rod
Chisel or something similar
Mole grips

 [attachment=7]

 [attachment=8]

 [attachment=9]

step 1.
undo oil drain on the diff just below passenger side driveshaft and remove oil

step 2.
Using a pair of grips/pliers/mole grips get someone to lightly pull at the bush while you tap the back of the bush with a chisel until it comes free. Leaving the seal in tact ensures it does not scratch the rod and they will both come off together.


Here is an image of the bush and seal removed

 [attachment=10]

step 3.
Carefully push the new bush down the selector rod and using your bit of pipe carfully tap it into place.

step 4.
Slide new seal paying particular attention to the part numbers on the rubber seal pointing outwards so they can be seen at all times even when in situ. Use some grease to lubricate the selector rod when doing so and use the metal pipe again and gently tap into position.

Step 5.
From above using a suitable funnel and pipe inserted into the top filling hole about 60mm above the drain hole fill the box with 3.1 litres of oil. Replace the drain plug and give everything a quick check over and a wipe.

So far it seems its stopped my leak and it also seems to have smoothened the selection of second gear. I think there was some play on the rod moving between the bush before hand which occasionally would interfere with a smooth selection of 2nd.

Note: i also used a tiny bit of sealer on the back of the lip of the bush which contacts with the box and used a bit of fine paper to carefully remove a few light scratches on the rod. nothing major, will be fine without these things being done, personal choice.

supercharged spaniel

[dannyb.G40]

Great "how to"... not as easy to get bush out as light tap with chizel (more like strength of the bear with a mallet and gradually fatter screwdrivers) but cheers for posting!

[Jezza-7]

Hayesey, is this a fairly easy thing to do?

[GR40]

Your attachments do not work and I am really looking forward in doing this too as my G leakes heavily from that seal! Could you please reattach them?

[hayesey]

the pictures are all at the bottom of the post. It got kind of messed up when we changed forum software some time back but they are all there.

[Jezza-7]

Just been vw to get bits, the bush has superseeded now and they gave me another one. When i pick them up on wednesday i will let you know.

[GR40]

just changed mine and it took me 10 hours to get the seal out  , a fair amount of WD40, 2 destroyed screwdrivers and pretty much every tool I had plus a couple borrowed! It shouldn't be that hard, my arms hurt from pushing and twisting and I don't want to do it ever again ! I guess that is what happens when you leave it there for 17years! Honestly a bigger lip on the end of it would make it hell easier to pull out, you would only need a spanner and a hammer, What were they thinking!

[liam]

i got round to doing this myself today after putting it off for weeks,

i didnt want to do it because some people said it was really hard to do,

mine took about ten minutes from start to finish and was really easy.

the pipe i used was a length of 22mm copper pipe smoothed at one end, worked perfect

[XRrich]

Do you know the size of the allen drain plug?

[hayesey]

17mm

[Jezza-7]

I did this the other day and it was a very easy thing to do. Used a scewdriver and a hammer. Taped under the bush to lever it out and it popped out. Guide is v.good though.