Removing and installing gear change mechanism — VW

Special tools and workshop equipment required

V.A.G 1331 Torque wrench

Removing operating cable with gear stick housing and support bracket.

Removing

Pull cover off frame.

Destroy clip (arrow 1) and pull gear lever knob off with gaiter.
Remove central console/gear stick housing securing nuts (arrows 2).

Remove insulation tray below engine/gearbox, if fitted.

Separate exhaust system below vehicle and detach from sub-frame if necessary.

=> Repair group 26; Removing and installing parts of exhaust system.
5-speed manual gearbox 085
Removing and installing parts of exhaust system.

Remove front (arrow) and rear cross supports, below the exhaust system.
Loosen front part of rear heat shield.
Remove front heat shield.
Unbolt selector housing from body.

Remove gear change cable (arrow A) and gate change cable (arrow B)

Remove angle piece (arrows) for support bracket from assembly carrier.

Remove nut (arrow) for support bracket and pull off support bracket.
Unbolt gear stick housing from body.
Take out operating cables with gear stick housing and support bracket.

Installing

Installation is carried out in the reverse sequence, when doing this note the following:

Adjusting gear change linkage => Page
34-22
.

Removing and installing gear stick lever and relay lever mounting bracket

Removing

Remove insulation tray below engine/gearbox, if fitted.
Remove gear change cable (arrow 1) and gate change cable (arrow 2).
Unscrew gate change rod with ball head (arrow 3) from selector finger.
Remove selector finger by loosening bolt (arrow 4).

Unscrew mounting bracket from gearbox (arrows).

A = Commercially available 13 mm AF, 3/8" square drive deep socket and universal joint.

Installing

Installation is carried out in the reverse sequence, when doing this note the following:

Installation position of gearbox selector lever, relay lever, gate rod and selector lever

1 -
Gear change cable
2 -
Gear change lever
is inserted into selector finger (arrow A)

3 -
Gate change cable
4 -
Relay lever
5 -
Mounting bracket
6 -
Selector finger
7 -
Gate rod

The step (arrow B) points towards selector finger.

Note:

For ease of illustration the support bracket for gear change cable and gate change cable is not shown.

Adjusting gear change linkage => Page
34-22
.

Removing and installing gear change lever and relay lever mounting bracket

Special tools and workshop equipment required

1 - Kukko 21/1 Internal puller
1 - Kukko 21/2 Internal puller
4 - Kukko 22/2 Counter support

Pulling out bearing bush for gear change lever

A - Internal extractor 14 ... 19 mm, e.g. Kukko 21/2

B - Counter support, e.g. Kukko 22/2

Pulling out bearing bush for relay lever

A - Internal extractor 8 ... 12 mm, e.g. Kukko 21/01

B - Counter support, e.g. Kukko 22/2

C - Adapter from counter support Kukko 22/1

Press bushes in with a vice. They only fit in one position.
Use vice clamps so that the bushes are not damaged.