Adjusting gear selector mechanism up to 05.99 — VW

02J
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

3422 Gear lever gauge

3192/1 Wedge

Notes:

The following points are essential to ensure correct selector adjustment:

Moving parts of selector mechanism and transmission elements must be in proper condition.
Selector mechanism must move freely.

The gearbox, clutch and clutch mechanism must also be in proper condition.

Gearbox in neutral position.

Carefully lever the cover off the centre console (arrows).
Pull cover to rear off the centre console.

Destroy clip (arrow) and pull gear stick knob off with cover.
Remove rubber cover, if fitted.

Remove intake hose -1- , connector -2- and hose -3- from air mass meter.
Remove complete air cleaner housing, to do this, unscrew bolts -4- and -5-.

=> Repair group 24; Removing and installing air cleaner
5-speed manual gearbox 02J
Removing and installing air cleaner

Remove balance weight => Page
34-7
.
Loosen bolt -A- and nut -B-, until the gear selector cable and actuating arm/gate selector cable are free to move in the elongated holes.

Loosen bolt -C-, pull off foam seal in area of bolt -C- if necessary.
Insert gear stick jig.
Swing jig securing hook under mounting plate and tighten nut -D-.
Press gear stick into left-hand detent of sliding piece.
Press gear stick together with sliding piece to left onto stop (direction of arrow) and tighten sliding piece with bolt -E-.

Press gear stick into the right-hand detent (direction of arrow).
Tighten bolt -C-.

Insert wedge and pin.

Slide wedge between gear selector lever and selector cover plate, ensuring no play.

Note:

Wedge must not lift gear stick.

In this position secure gear selector cable and actuating arm/gate selector cable, when doing this, check position of wedge.
Remove gear stick jig.
Fit balance weight => Page
34-7
.
Then assemble air intake duct

=> Repair group 24; Servicing injection system
5-speed manual gearbox 02J
Servicing injection system

Fit gear stick knob and gaiter.

Functional check

The gear stick lever must rest in the 3rd/4th gear gate with gearbox in neutral.

Operate clutch.
Select all gears several times. Pay particular attention to the operation of the reverse gear lock.

Should a gear fail to engage smoothly after repeated selection, the selector shaft play (lift) should be checked as follows:

Engage 1st gear.

Press gear stick to left onto stop and release.
At the same time observe selector shaft in gear box (2nd mechanic).
When moving the gear stick the selector shaft must move approx. 1 mm (in direction of arrow).

Should this not be the case, disengage first gear and again loosen nut -A- for the actuating arm/gate selector cable mounting. (The gate selector cable has a certain amount of play at the mounting - due to the transfer elements).
Take up gate selector cable play, by lightly pressing the mounting towards the bulkhead (direction of arrow).
Tighten nut -A- in this position.