Volkswagen Workshop Service and Repair Manuals

Assembly overview - gear selector relay points on gearbox

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Drift -VW 207 C-

t	Drift -10 - 206-

Lubricate bearing positions and sliding surfaces with grease -G 000 450 02-.

1 -	Self-locking hexagon nut, 20 Nm

q	Always renew

q	Gearbox selector lever to gearbox.

2 -	Gearbox selector lever

q	Fits onto selector shaft in one position only.

3 -

Seal

4 -	Coupling rod

5 -	Gear selector rod, front

q	Removing bushes → Fig..

q	Installing bushes → Fig..

6 -

Bracket

q	With relay lever and intermediate lever.

q	Removing and installing relay lever and intermediate lever → Fig..

q	Removing selector rod bush from intermediate lever → Fig..

q	Installing selector rod bush in intermediate lever → Fig..

q	Modification from 08.98: new bracket → Fig..

q	Attachment of new bracket to gearbox through 08.98 → Fig..

7 -	Coupling rod

8 -	Gear selector rod, front

q	With damper weight

9 -	Heat shield

q	Fit onto gate lever.

10 -	Hexagon bolt

q	Selector rod to clamp.

11 -

Clamp

12 -

Plug

13 -	Selector rod

14 -	Self-locking hexagon flange nut, 20 Nm

q	Selector rod to clamp.

15 -	Selector lever

16 -	Mounting bracket

q	With relay shaft.

q	Removing and installing relay shaft → Fig..

q	Removing selector rod bush from relay lever → Fig..

q	Installing selector rod bush in relay lever → Fig..

17 -	Heat shield

18 -	Hexagon bolt, 25 Nm

19 -	Hexagon bolt, 25 Nm

q	Bracket to gearbox

20 -

Gearbox

Pressing bushes out of selector rod

Pressing bushes into selector rod –  Coat bush lightly with grease and carefully press in on collar -arrow-.

Removing and installing relay lever and intermediate lever 1 -  Securing clip: push on to stop 2 -  Intermediate lever 3 -  Mounting bush; must engage in intermediate lever 4 -  Bracket 5 -  Mounting bush; must engage in bracket 6 -  Relay lever

From 08.98, new bracket for relay lever and intermediate lever New bracket -1- is mounted in rubber grommets -2- and mounting bushes -3-. 1 -  Bracket with larger mounting holes for rubber grommets and mounting bushes 2 -  Rubber grommet 3 -  Bearing bush 4 -  Hexagon bolt M 8 x 135 5 -  Hexagon nut M 8; always renew