Assembling the Gearshift Mechanism

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

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

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

The spring sides 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 Side Inserted From Above Into Guide & Pulled Down Near Guide To Position

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

NOTE:

The gearshift lever must be removed in order to insert the gearshift housing with the shift lever guide into the Press Piece - Block T10083.

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

Fig 3: Identifying Pins Located In Shift Housing Opening

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

-- Turn the shift lever guide in 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 Press Piece - 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 selector housing as far as stop.

Fig 5: Identifying Spring Side Inserted From Above Into Guide & Pulled Down Near Guide To Position
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The selector bracket is only partially shown to provide a better graphic.

-- 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 Press Piece - Block T10083.

-- Move the selector bracket all the way to the rear opposite mounting holes for shift and selector cable in direction of -arrow 1-.

-- 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.

Fig 6: Identifying Selector Bracket Moved Back As Far As Stop & Ball Head Pins Pressed Into Selector Bracket
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-- Place the shift housing with the shift lever guide into the larger cavity -arrow- in the Press Piece - Block T10083.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- 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 Press Piece - 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 in direction of -arrows-.

All retaining tabs must engage.

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

Fig 9: Attaching the Base Plate to the Shift Housing

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-- Install a new seal on the base plate.

CAUTION:

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

Tension the gearshift housing only slightly.

-- 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 -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 graphic).

-- The tabs can be bent back over using the Wedge T10357.

-A- = Counter-Support for example, from Kukko Model Line 16

-- Glue a new seal on the gearshift housing.

-- Install the gearshift mechanism, refer to SELECTOR MECHANISM, REMOVING AND INSTALLING .

-- Adjust the gearshift mechanism, refer to SELECTOR MECHANISM, ADJUSTING .