Adjusting shift mechanism with 2nd gear engaged — VW

Adjusting shift mechanism with 2nd gear engaged
Special tools and workshop equipment required
Locking pin
T10027
Adjusting gauge
T10217
Note configuration of selector mechanism in vehicles up to model year 2009:
Adjustment hole
arrow B
in gear lever points towards front of vehicle.
If the manual gearbox is equipped with a retaining pin, is it not used to adjust the shift mechanism.
The following points are essential to ensure correct adjustment of selector mechanism:
Moving parts of operating elements and elements transferring force must be in proper condition.
Selector mechanism must move freely.
Gearbox, clutch and clutch mechanism must also be in proper condition.
Gearbox in neutral at the start of procedure.
Note
Some of the illustrations in the working sequences below show the selector mechanism of the 6-speed manual gearbox. They are identical for the 5-speed manual gearbox together with the working sequences described here.
Pull selector lever sleeve up out of gear lever panel and slip over selector lever knob.
Multivan
Remove centre left knee padding
Rep. gr.
70
.
Transporter
Remove middle footwell trim
Rep. gr.
70
.
All vehicles
Push down locking mechanism for cable end-piece
A
on gear selector cable to stop
arrow
.
Push down locking mechanism for cable end-piece
1
on gate selector cable to stop
arrow
.
Engage 2nd gear using gearbox selector lever as follows:
In order to gain access to selector shaft, it may be necessary to remove engine cover panel.
Push
adjusting gauge
T10217
between gearbox selector lever
A
and selector mechanism cover
B
from in front onto selector shaft to stop.
At the same time, press gearbox selector lever and selector shaft down against
adjusting gauge
T10217
to stop in
direction of arrow 1
.
Now shift gearbox selector level to back
direction of arrow 2
.
Remove
adjusting gauge
T10217
from selector shaft.
Now secure selector lever as follows:
Move gear lever in neutral leftwards into selector lever gate for 1st and 2nd gears.
Guide
locking pin
T10027
through hole
A
of gear lever into hole
B
of selector housing.
Now press in
direction of arrow
against lug of securing mechanism for cable end-piece
1
on gate selector cable.
Spring presses locking mechanism into original position.
Then press in
direction of arrow
against lug of securing mechanism for cable end-piece
A
on gear selector cable.
Spring presses locking mechanism into original position.
Pull
locking pin
T10027
out of holes of gear stick
A
and selector housing
B
.
Shift gearbox to neutral position, and check function of selector mechanism.
Multivan
Install centre left knee cushion
Rep. gr.
70
.
Transporter
Install middle footwell trim
Rep. gr.
70
.
Continuation for all vehicles
Clip selector lever sleeve into gear lever panel.
Functional check
With gearbox in neutral, selector lever must rest in selector lever gate for 3rd and 4th gear.
Depress clutch pedal.
Select all gears several times. Pay particular attention to operation of reverse gear lock.
Should a gear fail to engage smoothly after repeated selection, vertical play of selector shaft should be checked as follows:
Engage 1st gear.
Press gear lever left to stop and release.
At the same time, a second mechanic should observe selector shaft in gearbox.
When gear lever is moved, selector shaft must have approximately 1 mm clearance
in direction of arrow
.
If this is not the case, adjust selector mechanism
Chapter
.