Shift Mechanism
Shift Mechanism
Special tools, testers and auxiliary items required
• Release Tool (T10236)
• Thrust Disc (VW 412)
• Assembly Tool (T10178) or Flat Iron, 200 x 25 x 5
• Adapter (10-222 A/25) or Flat Iron, 350 x 30 x 5
• Counter Support, for example, from Kukko Series 16 (Quantity: 2)
• Wedge (T10357)
• Thrust Block (T10083)
Disassembly
- Remove the shift mechanism. Refer to => [ Shift Mechanism ] Shift Mechanism.
- Remove the gasket from the shift housing.
- Bend down the tabs - arrows - on the shift mechanism base plate using a screwdriver and remove the base plate. The tabs on the front of the base plate are not illustrated.
- Remove the gasket from the shift housing.
- Remove the shift and selector cables from the shift housing. Refer to => [ Shift and Selector Cables ] Shift and Selector Cables.
- Lift the upper end - A - of the pressure spring over the tab on the selector bracket.
- Using a screwdriver, press the bearing shell notches - arrows - in the direction of the shift lever guide bearing; breaking of the notches if necessary.
- Pry out the bearing shell - A - with the shift lever guide - B - from the selector housing.
- Then, press the bearing shell off the shift lever guide bearing and remove it.
• Pay attention to the guides - A - in the next step.
• They must not break off.
- Lift the bottom end - arrow 1 - of the pressure spring onto the shoulder on the selector bracket.
- Now, raise the shift lever guide up as far as the stop and remove the ball studs from the selector bracket - arrow 2 -.
- Turn the shift lever guide in the - direction of arrow 1 -.
• The pins - arrow 2 - must be in the shift housing opening.
- Move the shift lever guide and the shift lever in the - direction of arrow 3 -.
Assembly
The lower side of the spring - arrow 1 - can spring down uncontrolled from the selector bracket shoulder during subsequent handling.
- Push the lower end carefully from the selector bracket shoulder.
The spring sides then twist "diagonally" with a loud noise.
- Release the tension on the ends - A and B - by turning both ends to the right.
• The ends - A and B - must face in the opposite direction.
• The selector shaft must be removed in order to insert the shift housing with the selector shaft guide into the thrust block (T10083).
- Install the shift lever guide into the shift housing.
• The pins - arrow 1 - are still located in the shift housing opening.
- Turn the shift lever guide in the - direction of arrow 2 - until the ball stud - A - is above the opening in the shift housing.
- Place the shift housing with the shift lever guide into the larger cavity - arrow - in the thrust block (T10083).
• The shift lever guide must project out of the selector housing as far as the stop.
• The selector bracket is only partially shown to provide a better illustration.
- Insert the end - A - of the pressure spring into the guide from the top.
- Pull the end - B - of the pressure spring downward and insert it next to the guide (toward the ball head).
- Carefully remove the shift housing and shift lever guide from the thrust block (T10083).
- Move the selector bracket all the way to the rear opposite mounting holes for the shift and selector cables - arrow 1 -.
- Grease the ball stud.
- Press the ball stud into the selector bracket - arrow 2 -.
• The guides - A - and the tabs - B - must not be damaged.
- Place the shift housing with the shift lever guide into the larger cavity - arrow - in the thrust block (T10083).
• The shift lever guide must project out of the selector housing as far as the stop.
- Pry the upper end - A - of the pressure spring over the pin on the selector bracket.
• Use a new bearing shell - B -.
- Grease the bearing shell and the shift lever guide bearing.
- Press the bearing shell all the way onto the shift lever guide bearing.
- Remove the shift housing from the thrust block (T10083).
- Insert the bottom end - C - of the pressure spring into the guide.
- Pry the upper end - A - of the pressure spring over the pin on the selector bracket.
- Push the bearing shell into the shift housing - arrows -.
• All retaining tabs must engage.
Attaching the Base Plate to the Shift Housing
- Install a new gasket on the base plate.
There is a danger of causing damage to the shift housing and base plate.
Tension the shift housing only slightly.
- A 200 x 25 x 5 flat iron can be used in place of the assembly tool (T10178).
- A 350 x 30 x 5 flat iron can be used in place of the adapter (10-222 A/25).
- Bend the tabs - arrow - back up all around the base plate to secure it (only the tabs on the left side of the base plate are shown in the illustration).
- Bend the tabs back up using the wedge (T10357).
- A - = counter-support, for example, from Kukko series 16
- Glue a new gasket (- item 17 - in the => [ Shift Lever and Housing Overview ] Shift Lever and Housing Overview) on the shift housing.
- Install the shift mechanism. Refer to => [ Shift Mechanism ] Shift Mechanism.
- Adjust the shift mechanism. Refer to => [ Shift Mechanism, Adjusting ] Adjustments.