Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ Gear stick jig 3192

Gearbox in neutral.

• ‒ Remove gear stick knob and gaiter
• ‒ Remove balance weight => from Page 34-4 .
• ‒ → Loosen bolt -A- and nut -B-, until the gear selector cable and actuating arm/gate selector cable are free to move in the elongated holes.

• ‒ → Loosen bolt -C-.
• ‒ Insert gear stick jig.
• ‒ Swing jig securing hook under mounting plate and tighten nut -D-.
• ‒ Press gear stick into left-hand detent of sliding piece.
• ‒ Press gear stick together with sliding piece to left onto stop (direction of arrow) and tighten sliding piece with bolt -E-.

• ‒ → Press gear stick into the right-hand detent (direction of arrow).
• ‒ Tighten bolt -C-.

• ‒ Insert wedge and pin.

• ‒ → Slide wedge between gear selector lever and selector cover plate, ensuring no play.

Note:

Wedge must not lift gear stick.

• ‒ In this position secure gear selector cable and actuating arm/gate selector cable, when doing this, check position of wedge.
• ‒ Remove gear stick jig.
• ‒ Fit gaiter/gear stick knob .

Functional check

• ● The gear stick lever must rest in the 3rd/4th gear plane with gearbox in neutral.

• ‒ Depress clutch, start engine, wait approx. 3 ... 6 secs. to allow gearbox input shaft to come to standstill.
• ‒ Select all gears several times. Pay particular attention to the operation of the reverse gear catch.

Should a gear fail to engage smoothly after repeated selection, the selector shaft play (lift) should be checked as follows:

• ‒ Engage 1st gear.

• ‒ Press gear stick to left onto stop and release.
• ‒ At the same time observe selector shaft in gear box (2nd mechanic).
• ‒ → When moving the gear stick the selector shaft must move approx. 1 mm (in direction of arrow).

• ‒ → Should this not be the case, disengage first gear and again loosen nut -A- for the actuating arm/gate selector cable mounting. (The gate selector cable has a certain amount of play at the mounting - due to the transfer elements).
• ‒ Take up gate selector cable play, by lightly pressing the mounting towards the bulkhead (direction of arrow).
• ‒ Tighten nut -A- in this position.

Notes:

The following are prerequisites for correct gear linkage adjustment:

• ◆ Perfect gear linkage operating and transfer elements.
• ◆ Rubber bushes for mounting the gear and gate selector cables to all operating elements in good condition (not worn).
• ◆ Gear and gate selector cables move smoothly.

Gearbox, clutch and clutch release mechanism must also be in good condition.