Shift Mechanism: Assembly

Fig 1: Identifying Ball Studs On Selector Bracket And Shift Lever Turned In

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION: The lower leg of the spring -arrow 1 - can spring down uncontrolled from the selector bracket shoulder during subsequent handling.

-- Push the lower leg carefully from the selector bracket shoulder.

The spring slides then twist "diagonally" with a loud noise.

-- Release the tension on the ends -A and B- by turning both ends to the right.

Fig 2: Identifying Spring Ends Facing In Opposite Directions

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The ends -A and B- must face in the opposite direction.

NOTE: The selector shaft must be removed in order to insert the shift housing with the selector shaft guide into the thrust block.

-- Install the shift lever guide into the shift housing.

Fig 3: Identifying Pins Located In Shift Housing Opening

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The pins -arrow 1- are still located in the shift housing opening.

-- Turn the shift lever guide in the -direction of arrow 2- until the ball stud -A- is above the opening in the shift housing.

-- Place the shift housing with the shift lever guide into the larger cavity -arrow- in the thrust block T10083.

Fig 4: Identifying Selector Housing With Shift Lever Guide Placed In Larger Depression On Pressing Support T10083

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The shift lever guide must project out of the selector housing as far as the stop.

Fig 5: Identifying Spring Ends Facing In Opposite Directions
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NOTE: The selector bracket is only partially shown to provide a better illustration.

-- Insert the end -A- of the pressure spring into the guide from the top.

-- Pull the end -B- of the pressure spring downward and insert it next to the guide (toward the ball head).

-- Carefully remove the shift housing and shift lever guide from the thrust block T10083.

-- Move the selector bracket all the way to the rear opposite the mounting holes for the shift and selector cables -arrow 1-.

Fig 6: Identifying Selector Bracket Moved Back As Far As Stop & Ball Head Pins Pressed Into Selector Bracket

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-- Grease the ball stud.

-- Press the ball stud into the selector bracket -arrow 2-.

The guides -A- and the tabs -B- must not be damaged.

-- Place the shift housing with the shift lever guide into the larger cavity -arrow- in the thrust block T10083.

Fig 7: Identifying Selector Housing With Shift Lever Guide Placed In Larger Depression On Pressing Support T10083

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The shift lever guide must project out of the selector housing as far as the stop.

Fig 8: Identifying New Bearing Shell To Raise Upper Side Of Spring Over Selector Bracket Pins
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pry the upper end -A- of the pressure spring over the pin on the selector bracket.

Use a new bearing shell -B-.

-- Grease the bearing shell and the shift lever guide bearing.

-- Press the bearing shell all the way onto the shift lever guide bearing.

-- Remove the shift housing from the thrust block T10083.

-- Insert the bottom end -C- of the pressure spring into the guide.

-- Pry the upper end -A- of the pressure spring over the pin on the selector bracket.

-- Push the bearing shell into the shift housing -arrows-.

All retaining tabs must engage.

-- Install the shift lever, the shift cable, the selector cable and the base plate. Refer to SHIFT LEVER AND HOUSING .

-- Secure the shift cable and selector cable on the shift housing with lock washers -2- and -3-.

Fig 9: Identifying Shift Lever And Selector Cable

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-- Install the shift cable -1- on the shift lever and selector cable -4- on the selector lever inside the shift housing.

Fig 10: Attaching Base Plate To Gearshift Housing

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-- Install a new seal on the base plate.

CAUTION:

There is a danger of causing damage to the shift housing and base plate.

Tension the shift housing only slightly.

-- Bend the tabs -arrow- back over all around the base plate to secure it (only the tabs on the left side of the base plate are shown in the illustration).

NOTE:

If only one Over-Center Spring Assembly Tool T10178 is available, instead of a second Over-Center Spring Assembly Tool T10178 the Toothed Belt Tensioner T10020 can be used instead.

A 200 x 25 x 5 flat iron can be used in place of an Over-Center Spring Assembly Tool T10178.

A 350 x 30 x 5 flat iron can be used in place of an Engine Support Bridge - Engine Support 2510-222A /25.

-- Bend the tabs back over using Wedge T10357.

- A- = Counter-Support for example the Counterstays Kukko 22/4.

-- Glue a new seal on the shift housing.

-- Install the shift mechanism. Refer to SHIFT MECHANISM .