Volkswagen Golf Variant / Jetta. Manual - part 275

 

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Volkswagen Golf Variant / Jetta. Manual - part 275

 

 

Note

If the relay lever cannot be removed due to the transmission

bracket, remove selector cable from relay lever. Remove the slide

shoe from the transmission shift lever.

Plastic Relay Lever
– Remove the relay lever with the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89

 .

Continuation for All Shift Mechanisms
– Remove the nut -4- and the transmission gearshift lever -1-.

– Pry out the seal using the Puller - Crankshaft/Power Steering

Seal - 1 - T20143/1- .

– Lightly oil the new gasket on the outer edge.
– Fill the space between the sealing/dust lip -arrow- halfway with

Sealing Grease - G 052 128 A1- .

14. Shift Unit, Servicing    

275

VW423- .

Install in reverse order of removal.
– Attach the transmission gearshift lever to the gearshift shaft

-item 1- 

⇒ Item 1 (page 273)

 and tighten the nut to the tight‐

ening specification.

Note

The gearshift lever can be installed in only one position.

– Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97

 .

– If it was removed earlier install the complete air filter housing.

Filter; Air Filter Housing, Removing and Installing .

276

Shift Forks, Servicing

Special tools and workshop equipment required
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW411-
♦ Press Piece - Multiple Use - VW426-
♦ Press Piece - Multiple Use - VW431-
♦ Puller - Kukko Internal - 18.5-23.5mm - 21/3-
♦ Puller - Kukko Counterstay - 22/1-

1 - Rubber Damper

❑ Can be removed and in‐

stalled by hand

2 - Gearshift Rod with 1st Gear

and 2nd Gear Shift Fork
3 - Gearshift Rod with 3rd Gear

and 4th Gear Shift Fork
4 - Gearshift Rod with 5th Gear

and 6th Gear Shift Fork

❑ On some transmission,

is also for the reverse

gear shift fork bearing

5 - Reverse Gear Shift Fork

❑ On the axle for the re‐

verse gear shift fork. Re‐

fer to

⇒ Fig. ““The Reverse

Gear Shift Fork -1- is

Mounted on the

Axle -2- behind the 5th

and 6th Gear Shift

Rod -3-.”“ , page 254

❑ From transmission

manufacture date

3/6/06, ball sleeve

-item 6-

⇒ Item 6 (page 277)

 has

been omitted

❑ Sliding omission
❑ Reverse gear shift fork

is adapted

❑ If the axle for the reverse

gear shift fork is deleted,

bearing on the shift rod

for the 5th and 6th gear

shift fork. Refer to

⇒ Fig. ““The Reverse Gear Shift Fork -1- is Mounted on the Gearshift Rod with the 5th and 6th Gear Shift

Fork -2-.”“ , page 254

❑ Reverse gear shift fork differentiation. Refer to

⇒ Fig. ““Reverse Gear Shift Fork Differentiation”“ , page 278

❑ Refer to the Parts Catalog.

6 - Ball Sleeve

❑ Removing. Refer to

⇒ Fig. ““Through Transmission Manufacture Date 3/5/06 - Remove Reverse Gear Shift Fork Ball

Sleeve”“ , page 278

 .

15. Shift Forks, Servicing    

277

⇒ Fig. ““Through Transmission Manufacture Date 3/5/06 - Press In Reverse Gear Shift Fork Ball Sleeve”“ ,

page 278

 .

❑ From transmission manufacture date 3/6/06, ball sleeve has been omitted
❑ Sliding omission

Reverse Gear Shift Fork Differentiation

Dimension “a” mm Reverse Gear Shift

Fork

Mounting

24

with ball sleeve

On the axle for the re‐

verse gear shift fork.

Refer to

⇒ Fig. ““The Reverse

Gear Shift Fork -1- is

Mounted on the

Axle -2- behind the

5th and 6th Gear Shift

Rod -3-.”“ , page 254

18

without ball sleeve

15

without ball sleeve

Gearshift rod with

shift fork for 5th and

6th gear. Refer to

⇒ Fig. ““The Reverse

Gear Shift Fork -1- is

Mounted on the

Gearshift Rod with

the 5th and 6th Gear

Shift Fork -2-.”“ , page

254

Through Transmission Manufacture Date 3/5/06 - Remove Re‐

verse Gear Shift Fork Ball Sleeve
A - Internal Puller 18 to 23 mm , for example Puller - Kukko Internal

- 18.5-23.5mm - 21/3-
B - Counter Support , for example Puller - Kukko Counterstay -

22/1-

Through Transmission Manufacture Date 3/5/06 - Press In Re‐

verse Gear Shift Fork Ball Sleeve

278

 

 

 

 

 

 

 

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