Get OperationandHousing -> 1.9 Selector Mechanism, Removing and Installing Guide for Volkswagen Golf 4 Door Fifth Generation (2003-2008)

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Removing the Selector Cable Retainer from the Plastic Relay

Lever.

•

The relay lever is removed.

– Insert a flat-blade screwdriver -A- between the bushing -B- and

the relay lever.

Installing the Cable Retainer

•

The relay lever is removed.

The cable retainer may only be installed at the bushing

-arrow-.

•

The cable retainer must move freely on the relay lever.

It must be behind the tab -arrow 2-.

1.9

Selector Mechanism, Removing and In‐

stalling

Special tools and workshop equipment required

♦ Torque Wrench 1331 5-50Nm - VAG1331-

♦ Refer to the Parts Catalog for the grease allocation.

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Removing

– First check whether a coded radio is installed. If so, obtain the

anti-theft code.

– Disconnect the battery ground cable. Refer to ⇒ Electrical

Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and

Connecting .

– Remove the boot with the shifter knob and noise insulation.

Refer to

⇒ “1.4 Boot with Shifter Knob and Noise Insulation, Removing

and Installing”, page 79 .

– Remove the center console and the center console securing

bracket. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Con‐

sole .

– Remove the nuts -arrows-.

– Remove entire air filter housing if it is located over the selector

mechanism. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection

System; Air Filter Housing, Removing and Installing or ⇒ Rep.

Gr. 24 ; Air Filter; Air Filter Housing, Removing and Installing .

– Remove the gearshift cable lock washer -3- from the gearshift

lever -1-.

– Remove the shift cable from the pins -arrow-.

Metal Relay Lever

– Remove the selector cable circlip -4- from the relay lever -2-.

– Remove the selector cable from the pins -arrow-.

Plastic Relay Lever

Disconnecting the Cable Retainer from the Selector Cable

•

To avoid damage to the selector cable, the cable retainer must

be disconnected from the selector lever before removal.

– Pull the securing mechanism all the way forward in direction

of -arrow 1- and then unlock to the left in direction of

-arrow 2-.

– Press the relay lever forward (in the direction of -arrow 3-).

– Remove the relay lever with the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89 .

Continuation for All Shift Mechanisms

1. Shift Mechanism, Servicing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the cable bracket from the transmission -arrows-.

– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.

Gr. 50 ; Noise Insulation .

– Remove the tunnel braces. Refer to ⇒ Body Exterior; Rep.

Gr. 50 ; Tunnel Brace .

Vehicles with FWD

Caution

Risk of damaging the decoupling element.

♦ Do not bend the decoupling element more than 10°.

♦ Do not load the decoupling element.

♦ Do not damage the wire mesh on the decoupling element.

– Separate the front exhaust system front section at the double

clamp and remove it from the subframe. Refer to ⇒ Rep. Gr.

26 .

– Disengage exhaust system rear section and secure to the

body using for example using a wire. Remove the exhaust

system rear section, if necessary.

AWD Vehicles

– Remove the rear muffler from the retaining straps and remove

the rear section of the exhaust system.

– Remove the exhaust pipe. Refer to ⇒ Rep. Gr. 26 .

– Remove heat shield below the driveshaft.

– Remove the driveshaft. Refer to ⇒ Rear Final Drive; Rep. Gr.

39 .

Continuation for All

– Remove the underbody trim panel nuts -arrows-.

– Remove the lock washers -2 and 3-.

– Lower the underbody trim panel on the inside just enough until

the heat shield -1- for the center tunnel can be removed.

– Pivot shift housing downward and remove with cables.

Installing

Install in reverse order of removal. Note the following:

– Align the shift housing so that it is parallel to the body.

•

The distance on both sides to the body must be equal.

Install the gearshift housing. Refer to -item 26-

⇒ Item 26 (page 82) or -item 16- ⇒ Item 16 (page 84) .

– Attach the cable mounting bracket to the transmission and

tighten the bolts to the tightening specifications -item 6-

⇒ Item 6 (page 86) and -item 10- ⇒ Item 10 (page 86) .

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Route the cables -1- from the shift mechanism -2- to the trans‐

mission as follows:

•

The cables must run parallel to each other and must not cross

each other.

The cables must be routed inside the depression in the heat

shield -3-.

Note

The heat shield from above is shown in the magnified view.

A clip -A- holds the cables and heat shield to each other in place.

These holes have different diameters.

Cable retainer allocation. Refer to

⇒ Fig. ““Cable Retainer Allocation”“ , page 87

– Apply a small amount of grease on the pins on the transmis‐

sion shift lever -arrows- -1- and on the relay lever -2-.

•

Refer to the Parts Catalog for the grease allocation.

– Replace the lock washer -3- and the lock washer -4- on the

metal relay lever each time they are removed.

– Secure shift cable with lock washer -3- and selector cable with

lock washer -4-.

Cable Retainer with Plastic Relay Lever

– The relay lever and cable retainer must be installed together.

Refer to ⇒ “1.8 Plastic Relay Lever”, page 89 .

– Insert the selector cable into the cable retainer.

Continuation for All Shift Mechanisms

– Install the bracket and the center console. Refer to ⇒ Body

Interior; Rep. Gr. 68 ; Center Console .

– Install the boot with the shifter knob and noise insulation. Refer

⇒ “1.4 Boot with Shifter Knob and Noise Insulation, Removing

and Installing”, page 79 .

1. Shift Mechanism, Servicing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the heat shield -1- under the selector mechanism and

attach with the lock washers -2 and 3-.

– Attach the underbody trim panel to the body -arrows-. Refer to

⇒ Body Exterior; Rep. Gr. 50 ; Underbody Trim Panels .

AWD Vehicles

– Install the driveshaft. Refer to ⇒ Rear Final Drive; Rep. Gr.

39 .

Continuation for All

– Install the exhaust system and align it without tension. Refer

to ⇒ Rep. Gr. 26 .

– Install the tunnel braces under the exhaust system. Refer to

⇒ Body Exterior; Rep. Gr. 50 ; Tunnel Brace .

– Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

– If it was removed earlier install the complete air filter housing.

Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Air

Filter Housing, Removing and Installing or ⇒ Rep. Gr. 24 ; Air

Filter; Air Filter Housing, Removing and Installing .

– Complete the steps after connecting the battery. Refer to ⇒

Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Discon‐

necting and Connecting .

1.10

Gearshift Cable and Selector Cable, Re‐

moving and Installing

Removing

– Remove the selector mechanism. Refer to ⇒ page 93 .

– Bend up the tabs -arrows- on the shift mechanism base plate

using a screwdriver and remove the base plate. Only the

straps on the left side of the base plate are shown in the illus‐

tration.

– Remove the seal.

– Remove the lock washers -1 through 4-.

Note

Lock washers -1 and 4- are no longer installed in shift mecha‐

nisms beginning in 11/2006.

– Pry off the shift cable (or the selector lever cable) from the

gearshift lever (or selector lever) with a screwdriver.

– Remove the shift cable and selector cable from the shift hous‐

ing.

Rep. Gr.34 - Operation and Housing

OperationandHousing -> 1.9 Selector Mechanism, Removing and Installing for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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