Shift Mechanism, Removing And Installing: Installing

NOTE:

Lubricate the bearing areas and the sliding surfaces. Refer to the Parts Information for the grease allocation.

-- Install the relay lever and cable retainer -arrow 2- all the way into the gearshift cover.

-- Install the clip -arrow 1- and make sure it is locked into place.

With the Selector Relay Lever Removed: Pry the Selector Cable Retainer out of the Selector Relay Lever.

Fig 1: Identifying Screwdriver To Pry Selector Cable Retainer Out Of Plastic Relay Lever

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The relay lever is removed.

-- Insert a screwdriver -A- between the bushing -B- and the relay lever.

Installing the Selector Cable Retainer on the Relay Lever

Fig 2: Identifying Direction To Press On Cable Retainer

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The relay lever is removed.
Lubricate cable retainer locating bore
Refer to the Parts Information for the grease allocation.
The cable retainer may only be installed at the bushing -arrow-.
The cable retainer must move freely on the relay lever.
The cable retainer must be behind the tab.
Make sure it engages securely.

Removing the Cable Retainer from the Gearshift Cable and Selector Cable

Fig 3: Identifying Sequence To Release Retainers -A- For Shift And Selector Cables -B-

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-- Pull the safety mechanism all the way forward -arrow 1- and lock it in direction of -arrow 2-.

-- Remove the cable -B- from the cable retainer -A-.

Shift Mechanism, Installing

Install in the reverse order of removal while noting the following:

Cable Retainer Allocation

Fig 4: Allocation Of Cable Retainers

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The holes in the cable retainers have different diameters.

Cable retainer for:	Dimension "a"
-1- Shift cable to gearshift lever	8.5 mm
-2- Selector cable to relay lever	10 mm

Shift Lever/Relay Lever Installation Position

Fig 5: Identifying Transmission Shift Lever Components

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Shift Lever
Clip
The relay lever engages into the slide block -arrow- in the shift lever guide rail.

Shift Lever, Installing

Fig 6: Identifying Installation Of Transmission Shift Lever

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-- When positioning the transmission shift lever, make sure the tooth gap -arrow A- is placed over the missing selector shaft teeth -arrow B-.

Relay Lever: Lubricate the Following Areas Very Carefully When Installing.

Fig 7: Identifying Relay Lever Shaft Lubrication Area

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Shaft -A- on the relay lever -arrows- ; quantity of grease: 0.2 grams
Refer to the Parts Information for the grease allocation.

Gearshift Lever: Lubricate the Following Areas Very Carefully When Installing.

Fig 8: Identifying Transmission Shift Lever Guide Rail Lubrication Area

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Gearshift lever guide rail -B-, fits into the relay lever.
Cable retainer locating bore.
Refer to the Parts Information for the grease allocation.
The relay lever and gearshift lever shown may differ from the original part.

-- Replace the gasket on the gearshift housing.

-- Align the shift housing so that is it parallel to the body.

The distance on both sides to the body must be equal.

-- Install the gearshift housing.

-- Route the cables -1- from the gearshift mechanism -2- to the transmission as follows:

Fig 9: Identifying Cables Routed From Selector Mechanism To Transmission

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The cables must be routed parallel to each other and must not cross each other.
The cables must be routed inside the depression in the heat shield -3-.

NOTE:

The heat shield from above is shown in the magnified area.

A clip -A- holds the cables and heat shield to each other in place.

Fig 10: Identifying Clip That Holds Cables In Place To Heat Shield

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-- Mount the cable bracket on the transmission and tighten the bolts -2- and nuts -1-.

Fig 11: Locating Bracket Nuts And Bolts

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The holes in the cable retainers have different diameters. Refer to Fig 4.

-- Apply a small amount of Grease on the pin -arrow- for the gearshift lever -1-.

Fig 12: Identifying Lock Washer -1- And Pin -Arrow- On Transmission Shift Lever -2-

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Refer to the Parts Information for the grease allocation.

-- Secure the shift cable with new lock washers -1- to the gearshift lever -2-.

-- Install the selector cable into the cable retainer on the relay lever.

-- Install the center console bracket and the center console. Refer to CENTER CONSOLE, REMOVING AND INSTALLING .

-- Adjust the gearshift mechanism. Refer to SHIFT MECHANISM, ADJUSTING .

-- Install the boot with the selector knob and if necessary, the noise insulation. Refer to GEARSHIFT KNOB, REMOVING AND INSTALLING .

Fig 13: Identifying Clamp

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-- Replace the clamp -arrow-.

-- Install the heat shield under the gearshift mechanism. Refer to HEAT SHIELD, REMOVING AND INSTALLING .

-- Assemble the exhaust system free of tension. Refer to [For engine(s) DKFA] Exhaust Pipes/Mufflers .

-- Install the entire air filter housing.

Vehicles with turbo diesel engine. Refer to the appropriate Service Information
Vehicles with a gasoline engine. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING

-- Install the battery tray, battery and the battery cover. Refer to BATTERY, REMOVING AND INSTALLING .