4.1 Disassembling, Assembling, and Adjusting Shift Mechanism

Fig. 4-2 is an exploded view of the shift mechanism used with five-speed manual transmissions. It can be used as a guide for disassembling and assembling the linkage, to replace any worn bushings, or when removing the transaxle. When removing the selector rods, use a screwdriver to press back the clips on the plastic rod ends before pulling them off of the ball pins on the levers. When assembling, remove any white grease from the linkage and lubricate all joints and pivot points with molybdenum disulphide grease (Volkswagen part no. G 000 602). A special Volkswagen gauge is required to accurately adjust the shift mechanism after installing new parts, or to correct shifting difficulties.

Fig. 4-2.

Exploded view of shift mechanism. Inset shows new relay shaft and selector lever used on models produced since mid-1985.