M/T - Pops Out of Gear

Group: 34

Number: 97-03

Date: Apr. 11, 1997

Subject:
Transmission Pops Out of Gear, Shifter Feels Like it has a Double Detent When Shifting into gear

Model(s):
Golf, GTI, Jetta w/02A Trans 1996 --> 1997
Passat w/02A, 02C Trans 1996 --> 1997

Condition

Transmission pops out of gear, shifter feels like it has a double detent when shifting into gear, will not maintain shift adjustment.

May be caused by a hairline crack on selector shaft shift detent sleeve which allows sleeve to become dislocated on the selector shaft.

Service

If condition exists, remove external shift controls from the selector shaft/transmission as follows:





- Remove electrical connector from back-up light switch housing.

- Remove nut -B- and balance weight -A- from gear selector cable attachment.

- Remove gear selector cable from gear selector lever.

- Disconnect gate selector cable from actuating arm/relay lever -C- by lifting lug in direction of -arrow-.

- Remove 2 bolts securing back-up light switch housing -D- and remove housing.





- Remove self locking nut -7- and back-up light switch cam sleeve -6-.

- Remove gear shift lever -12-.





- Remove selector shaft housing attachment bolts -arrows- (tap housing lightly with brass or plastic mallet to loosen).

- Remove selector shaft and housing from transmission.

- Remove selector shaft from housing.

Note:
Shaft should slide freely in and out of housing without binding. If shaft binds, housing should be replaced (see Technical Bulletin 34-97-02)





- Clamp selector shaft in a vise (with jaw protectors), then using a pair of pliers try to rotate clamping sleeve -A- on selector shaft.

If sleeve rotates:

- Install new selector shaft

Part No: 02A 301 233F into selector shaft housing (ensure that selector shaft moves freely in housing).

- Remove new selector shaft from housing and install into transmission.

- Install selector shaft housing using sealant AMV 188 200 03 or equivalent.

^ Torque bolts to 25 Nm. (18 ft. lb.).

- Reinstall gear shift lever.

- Reinstall back-up light switch cam sleeve (always use a new self locking nut).

^ Torque nut to 25 Nm. (18 ft. lb.).





- Lift lug -C- in direction of -arrow- and reinstall gate selector cable to actuating arm/relay lever.

- Reconnect gear selector cable to gear selector lever (position cable pivot in center of slot on selector lever).

- Reinstall balance weight -A-.

- Reinstall back-up light switch housing -D-.

- Reinstall back-up light switch electrical connector.

- Road test vehicle.

When procedure applies to vehicles within warranty use the following:

Part Identifier: 3445
Labor Operation: 3445510 90 TU