Gear Selector Mechanism, Adjusting

5 Speed Manual 02J

Gear Selector Mechanism, Adjusting

Special tools






- 3422 Shift lever Adjusting Fixture






- 3192/1 Wedge

Note:

- The following points are essential to make sure correct selector adjustment:
- Moving parts of selector mechanism and transmission elements must be in proper condition.
- Selector mechanism must move freely.
- The transmission, clutch and clutch mechanism must also be in proper condition.

- Transmission in neutral position.






- Carefully pry cover off center console (arrows).
- Pull cover to rear of center console.






- Destroy clip (arrow) and pull gear lever knob off with cover.
- Pull rubber noise damper off gear lever.
- Obtain radio code on vehicles with coded radio.
- With ignition switched off disconnect battery ground strap.






- Pull intake hose -1 - and connector -2-off air mass meter.
- Remove bolts -3-, -4- and -5-.
- Remove air cleaner complete.
- Remove balance weight.






- Loosen bolt -A- and nut -B-, until gear selector cable and actuating arm/gate selector cable are free to move in elongated holes.






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






- Press gear lever into right-hand detent (direction of arrow).
- Tighten bolt -C-.
- Insert wedge and pin.





- Slide wedge between gear selector and selector cover plate, make sure there is no play.

Note:

- Wedge must not lift gear lever

- In this position secure gear selector cable and actuating arm/gate selector cable, when doing this, check position of wedge.
- Remove gear lever jig.
- Install balance weight ~4-7.
- Install gear lever knob and boot.

Functional check

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

- Operate clutch.
- Select all gears several times. Pay particular attention to operation of 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 lever to left onto stop and release.
- At same time observe selector shaft in gear box (2nd mechanic).






- When moving, gear selector lever shaft must move approx. 1 mm (in direction of arrow).







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