Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ 3422 Gear lever gauge

• ◆ 3192/1 Wedge

Notes:

The following points are essential to ensure correct selector adjustment:

• ◆ Moving parts of selector mechanism and transmission elements must be in proper condition.
• ◆ Selector mechanism must move freely.

The gearbox, clutch and clutch mechanism must also be in proper condition.

• ● Gearbox in neutral position.

• ‒ → Carefully lever the cover off the centre console (arrows).
• ‒ Pull cover to rear off the centre console.

• ‒ → Destroy clip (arrow) and pull gear stick knob off with cover.
• ‒ Remove rubber cover, if fitted.

• ‒ → Remove intake hose -1- , connector -2- and hose -3- from air mass meter.
• ‒ Remove complete air cleaner housing, to do this, unscrew bolts -4- and -5-.

=> Repair group 24; Removing and installing air cleaner

• ‒ Remove balance weight .
• ‒ → 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-, pull off foam seal in area of bolt -C- if necessary.
• ‒ 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 balance weight => Page 34-7 .
• ‒ Then assemble air intake duct

=> Repair group 24; Servicing injection system

• ‒ Fit gear stick knob and gaiter.

Functional check

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

• ‒ Operate clutch.
• ‒ Select all gears several times. Pay particular attention to the operation of the reverse gear lock.

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.