Volkswagen Golf Variant / Jetta. Manual - part 515

 

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Volkswagen Golf Variant / Jetta. Manual - part 515

 

 

1.9.2

Installing

Install in reverse order of removal while. Note the following:
– Secure the shift cable and selector cable on the shift housing

with lock washers -2 and 3-.

– Attach the shift cable and the selector cable to the gearshift

lever and the selector lever inside the shift housing and secure

it with lock washers -1 and 4-.

Note

Lock washers -1 and 4- are no longer installed in shift mecha‐

nisms beginning in 11/2006.

– Install the base plate with a new seal on the gearshift housing

-arrows-. Refer to

⇒ Fig. ““Base Plate, Attaching to Gearshift Housing”“ ,

page 66

 .

– Install the gearshift mechanism. Refer to

⇒ “1.8 Selector Mechanism, Removing and Installing”,

page 70

 .

– Adjust the gearshift mechanism. Refer to

⇒ “1.10 Selector Mechanism, Adjusting”, page 76

 .

1.10

Selector Mechanism, Adjusting

⇒ “1.10.1 Procedure”, page 76
⇒ “1.10.2 Function”, page 78

1.10.1

Procedure

Special tools and workshop equipment required
♦ Connecting Pin - T10027A-

76

The following is important to make sure the gearshift adjust‐

ment is correct:

Operating and transfer elements of shift mechanism must be

in proper condition.

Shift mechanism must move freely.

The transmission, clutch and clutch mechanism must also be

in proper condition.

• Transmission in neutral.
– Remove the air filter housing if the bracket for the selector

shaft and the securing mechanism for the shift and selector

Air Filter Housing, Removing and Installing .

– Pull the safety mechanism on the cable retainer for the shift

cable and the selector cable all the way forward in direction of

-arrow 1- and then lock it to the left in direction of -arrow 2-.

Secure the gearshift shaft as follows:
– Push the gearshift shaft down in direction of -arrow 1-.
– While press the gearshift shaft down, rotate the bracket -A- in

direction of -arrow 2- upward and simultaneously press it in

until it engages in the gearshift shaft.

– Remove the boot with the shifter knob and cover. Refer to

⇒ “1.4 Boot with Shifter Knob and Noise Insulation, Removing

and Installing”, page 55

 .

– If equipped, remove the noise insulation.
Secure the gearshift shaft as follows:
– Move the gearshift lever into neutral.

– Guide the Connecting Pin - T10027A- through the hole -A- and

into the hole -B-.

1. Shift Mechanism, Servicing    

77

the retainer -A- without tension.

– Turn the safety mechanism on the cable retainer for the shift

cable and selector cable all the way to the right in direction of

-arrow 1-.

The spring will push the safety mechanism into the starting posi‐

tion in direction of -arrow 2-.

– Then turn the bracket -A- in direction of -arrow- back into it

starting position.

Note

The bracket -A- must be pushed out of the selector housing as

far as the stop and it must face upward vertically.

– Pull the Mandrel out of the holes -A- and -B-.
– If equipped, install the noise insulation.
– Install the boot with the shifter knob and cover. Refer to

⇒ “1.4 Boot with Shifter Knob and Noise Insulation, Removing

and Installing”, page 55

 .

– Make sure the gearshift shaft moves easily.
– If removed, install the complete air filter housing. Refer to ⇒ 

Rep. Gr.  24 ; Air Filter; Air Filter Housing, Removing and In‐

stalling .

1.10.2

Function

• The shift lever must rest in the 3rd/4th gear selector lever gate

when the transmission is in neutral.

– Operate the clutch.
– Move the gearshift lever (selector lever) several times through

all the gears. Pay particular attention to the operation of the

reverse gear lock.

– Should a gear fail to engage smoothly after engaging it re‐

peatedly, adjust the gearshift mechanism again. Refer to

⇒ “1.10 Selector Mechanism, Adjusting”, page 76

 .

1.11

Plastic Relay Lever

A plastic relay lever is installed from 05/2007. Two versions may

be installed.
♦ Relay lever with tab or
♦ Relay lever with clip
Note the following when removing and installing:

78

retainer from the selector cable.

This prevents damage to the selector cable.
– Pull the securing mechanism all the way forward in direction

of -arrow 1- and then unlock to the left in direction of

-arrow 2-.

– Push the relay lever forward (direction of -arrow 3-).

Relay Lever with Tab -arrow 1-
– Push the catch -arrow 1- all the way down and remove the

relay lever and cable retainer. Move the relay lever in its op‐

erating direction.

Relay Lever with Clip -arrow 1-.
– Remove the clip -arrow 1- and then remove the relay lever and

the cable retainer.

Continuation for All
• The cable retainer must be behind the catch -arrow 2-.
• The cable retainer may only be removed with the relay lever

removed. Refer to

⇒ Fig. ““Removing the Selector Cable Retainer from the Plas‐

tic Relay Lever.”“ , page 80

 .

Note

Lubricate the bearing areas and sliding surfaces when instal‐

ling.

Refer to the Parts Catalog for the grease allocation.

– Press the cable retainer on the relay lever. Refer to

⇒ Fig. ““Installing the Cable Retainer”“ , page 81

 .

– Insert the relay lever together with the cable retainer as far as

the stop.

1. Shift Mechanism, Servicing    

79

 

 

 

 

 

 

 

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