Volkswagen Workshop Service and Repair Manuals

Assembly overview - removing and installing selector cables

t	Lubricate bearing positions and sliding surfaces.

t	Allocate grease using → Electronic parts catalogue (ETKA).

1 -	Gear selector cable

q	Connect to cable end-piece → Item

q	Installation position → Chapter

q	From 06.06, modified attachment to gear lever inside selector mechanism → Item

2 -	Gate selector cable

q	Connect to cable end-piece → Item

q	Installation position → Chapter

q	From 06.06, modified attachment to gate selector lever inside selector mechanism → Item

3 -	Securing clip

q	Always renew

q	Discontinued in gearbox mechanisms from 06.06 → Chapter

4 -	Selector housing

5 -	Securing clip

q	Always renew

q	Do not damage cables when removing

6 -	Hexagon bolt, 25 Nm

q

Qty. 3

q	For cable support bracket

7 -	Cable support bracket

q	May be made from plastic or metal

8 -

Grommet

q	Cable support bracket mounting on gearbox

9 -

Spacer

10 -	Cable end-piece

q	After installing, adjust selector mechanism → Chapter

q	For gate selector cable to relay lever

q	Through 10.04 - always renew after removing from relay lever

q	From11.04 with end-to-end holes.

q	From this date, not necessary renew

q	For metal relay lever from this date, secured with securing clip → Anchor

q	From 12.06, fitted in conjunction with plastic relay lever → Fig.

q	Removing from plastic relay lever → Fig.

q	Pressing onto plastic relay lever → Fig.

q	Allocation → Fig.

11 -	Cable end-piece

q	After installing, adjust selector mechanism → Chapter

q	For gear selector cable to gearbox selector lever

q	Through 10.04 - always renew after removing from gearbox selector lever

q	From 11.04 with end-to-end holes.

q	From this date, not necessary renew

q	Secured with securing clip → Anchor

q	Allocation → Fig.

12 -	Relay lever

q	Installation position →

q	After installing, adjust selector mechanism → Chapter

q	May be made from plastic or metal

q	Metal relay lever is mounted in 2 bushes and secured with a securing clip → Chapter

q	Always renew securing clip

q	From 12.06, plastic relay lever

q	Remove and install plastic relay lever together with cable end-piece → Fig.

q	Bearing bushes and securing clip not required for plastic relay lever

13 -

Shoe

14 -	Self-locking hexagon nut, 25 Nm

q	Always renew

15 -	Gearbox selector lever

q	Can be renewed with the selector mechanism installed

q	Installation position →

q	Installing → Fig.

q	After installing, adjust selector mechanism → Chapter

Allocation of selector mechanisms from 11.04 The holes in the cable end-pieces have different diameters.

Cable end-piece for	Dimension „a“
Gear selector cable to gearbox selector lever	10 mm
Gate selector cable to metal relay lever	8 mm
Gate selector cable to plastic relay lever	10 mm

Install gearbox selector lever –  When fitting the gearbox selector lever, ensure that the gap -arrow A- is aligned with the master spline -arrow B-.

Installation position of gearbox selector lever and relay lever l  Relay lever engages in guide rail of gearbox selector lever via shoe -arrow-.

Plastic relay lever l  To remove relay lever, first separate cable end-piece from gate selector cable.

This will avoid damage to the gate selector cable –  Pull locking mechanism forward to stop in -direction of arrow 1- and then lock by turning to left in -direction of arrow 2-. –  Then push relay lever forwards (-in direction of arrow 3-). Relay lever with catch -arrow 1- (⇒ previous diagram). –  Press catch -arrow 1- (⇒ previous diagram) down to stop and remove relay lever together with cable end-piece. In the process, swing it in direction of operation.

Relay lever with clip -arrow 1- –  Pull clip -arrow 1- off and remove relay lever together with cable end-piece. Cable end-piece must be located behind catch -arrow 2-. Continuation for all l  The cable end-piece can be removed only with the relay lever removed → Fig..   Note t  When installing, lubricate bearing positions and sliding surfaces. t  Allocate grease using → Electronic parts catalogue (ETKA). –  Press cable end-piece onto relay lever → Fig.. –  Install relay lever together with cable end-piece to stop. l  Catch -arrow 1- secures relay lever (⇒ previous diagram). l  Ensure proper engagement. l  Cable end-piece must be located behind catch -arrow 2- (⇒ previous diagram).

Levering gate selector cable end-piece off plastic relay lever l  Relay lever has been removed –  Insert a flat-blade screwdriver -A- between bush -B- and relay lever.

Pressing on cable end-piece l  Relay lever has been removed l  Cable end-piece may be pressed only onto bush -arrow-. l  Cable end-piece must move freely on relay lever. l  It must be located behind catch -arrow 2- → Fig..