Selector Mechanism, Removing and Installing

Selector mechanism, removing and installing - 6 Spd. Manual Transmission 02X All Wheel Drive

Special tools, testers and auxiliary items required





^ Engine/transmission jack V.A.G 1383 A

Removing

- Remove gear lever knob together with boot.

Vehicles with large radio slot:

- Remove air conditioning operating unit.

Vehicles with small radio slot:





- First lift trim panel - 1 - in direction of - arrow A -, then pull it out in direction of - arrow B -.

Continued for all vehicles:

- Remove bolts - arrows C - and then pull ashtray - 2 - out of center console.
- Disconnect electrical connector for ashtray light.
- Remove foam wedges from center console.
- Lift out sound insulation.





- Remove sound insulation for gear lever housing - arrows -.





- Remove nuts - arrows -.
- Remove both front wheels.
- On vehicles equipped with auxiliary heater, remove bolts - arrows - securing exhaust pipe of auxiliary heater to sound insulation.





- Loosen bolts/quick release fasteners - 1 - and - 2 - and remove front sound insulation - A -.
- If installed, loosen quick release fasteners - 3 - and remove rear sound insulation - B -.





- Remove bracket for sound insulation - arrows -.





- Disconnect exhaust system at clamps - arrows -.

Note:
^ The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10 degrees - otherwise it can be damaged.

^ The illustration shows the exhaust system in conjunction with the 3.0 liter. V6 engine.

- Disengage rear section of exhaust system at rubber mountings and remove.

Note:
^ A second technician is required for removing the rear section of the exhaust system.





- If installed, remove heat shield for drive shaft - arrows -.





- Remove heat shield - 1 - for exhaust system below selector mechanism - arrows -.
- Remove bolts at transmission/drive shaft flange.
- Push drive shaft - 2 - together toward rear final drive. The constant velocity joints can be moved axially.





- Tie drive shaft to side, onto heat shield - arrow -.





- Remove universal transmission mounting V.A.G 1359/2 from engine/transmission jack V.A.G 1383 A and place a wooden block - arrow - on press tool instead.
- Support rear cross member using engine and transmission jack V.A.G 1383 A.
- Remove bolts - 1 - and - 2 -, then bolts - 3 - and - 4 -.





- Carefully lower rear cross member with using engine and transmission jack V.A.G 1383 A until distance between rear cross member and body reaches dimension "x".

^ Dimension x = 60 mm





- Remove heat shield - arrow - for drive axle (right side) and, if installed, also for drive axle (left-side).





- Remove connecting rod - 2 - for selector rod.
- Disconnect push rod - 1 - by removing hex socket head bolt.





- Remove nut - arrow - and detach selector shaft lever from selector shaft.
- Remove selector mechanism to rear.

Installing

Installation is in reverse order of removal. Note the following:

Note:
^ Always replace seals, gaskets and self-locking nuts.

- Bolt drive shaft onto transmission.
- Install exhaust system free of stress.
- Install tunnel cross member.
- Adjust selector mechanism.
- Install air conditioning operating unit.

Tightening torques