Get OperationandHousing -> 1 Shift Mechanism, Servicing 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

34 – Operation and Housing

1

Shift Mechanism, Servicing

⇒ “1.1 Shift Mechanism Installation Position”, page 76

⇒ “1.2 Overview - Selector Mechanism”, page 78

⇒ “1.3 Overview - Gearshift Knob and Cover”, page 79

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

Installing”, page 79

⇒ “1.5 Overview - Gearshift Lever and Gearshift Housing, through

10/2006”, page 81

⇒ “1.6 Overview - Gearshift Lever and Gearshift Housing, from

11/2006”, page 83

⇒ “1.7 Overview - Operating Cables”, page 85

⇒ “1.8 Plastic Relay Lever”, page 89

⇒ “1.9 Selector Mechanism, Removing and Installing”,

page 92

⇒ “1.10 Gearshift Cable and Selector Cable, Removing and In‐

stalling”, page 96

⇒ “1.11 Selector Mechanism, Adjusting”, page 97

⇒ “1.12 Selector Mechanism, Disassembling and Assembling,

from 11/2006”, page 100

1.1

Shift Mechanism Installation Position

-Arrow A- Gearshift Lever Movement

-Arrow B- Selector Lever Movement

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

6-Speed Manual Transmission 02Q - Edition 05.2013

A - Gearshift Lever Cable

B - Selector Cable

C - Heat Shield

❑ Remove the gearshift

mechanism before re‐

moval

1 - Selector Lever

2 - Relay Lever

1. Shift Mechanism, Servicing

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6-Speed Manual Transmission 02Q - Edition 05.2013

1.2

Overview - Selector Mechanism

Note

♦ Get the anti-theft code for the radio before disconnecting the battery.

♦ Disconnect the ground cable from the battery when working on the gearshift mechanism inside the engine

compartment. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and Con‐

necting .

♦ Read the information on what to do after connecting the battery. Refer to ⇒ Electrical System; Rep. Gr.

27 ; Battery; Battery, Removing and Installing .

♦ To work on shift mechanism on engine compartment, remove entire air filter housing if it is located over the

shift 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 .

♦ The shift mechanism must be removed in order to replace the operating cables. Refer to

⇒ “1.9 Selector Mechanism, Removing and Installing”, page 92 .

♦ Do not bend the operating cables.

I -

⇒ “1.3 Overview - Gearshift

Knob and Cover”, page 79 .

II -

⇒ “1.5 Overview - Gearshift

Lever and Gearshift Housing,

through 10/2006”, page 81 .

II -

⇒ “1.6 Overview - Gearshift

Lever and Gearshift Housing,

from 11/2006”, page 83 .

III -

⇒ “1.7 Overview - Operating

Cables”, page 85

Gearshift mechanism, removing and installing. Refer to

⇒ “1.9 Selector Mechanism, Removing and Installing”,

page 92 .

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

6-Speed Manual Transmission 02Q - Edition 05.2013

Adjust the gearshift mechanism. Refer to

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

1.3

Overview - Gearshift Knob and Cover

1 - Badge

❑ Can be carefully pried

off a plastic or leather

shift knob

2 - Gearshift Knob

❑ With boot

❑ The shift knob and boot

cannot be separated

from each other.

❑ Always replace together

❑ Removing and instal‐

ling. Refer to

⇒ “1.4 Boot with Shifter

Knob and Noise Insula‐

tion, Removing and In‐

stalling”, page 79 .

3 - Clamp

❑ For securing the shift

knob to the shift lever

❑ Secure on the gearshift

knob -item 2-

⇒ Item 2 (page 79) using

Hose Clamp Pliers -

VAG1275- .

❑ Replace after removing

4 - Center Console Frame

❑ Combined in one piece

with the upper center

console section on

some versions

5 - Noise Insulation

❑ Not on all vehicles

❑ Arrow on noise insula‐

tion points in direction of

travel

❑ Retaining tab spacing varies

❑ Therefore can only be arranged in one position

1.4

Boot with Shifter Knob and Noise Insu‐

lation, Removing and Installing

Special tools and workshop equipment required

♦ Hose Clip Pliers - VAG1275A-

1. Shift Mechanism, Servicing

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6-Speed Manual Transmission 02Q - Edition 05.2013

Removing

– Remove the boot with the center console frame from the cen‐

ter console or pry it out carefully -arrows-.

Note

On some equipment versions, the boot must be pried out at the

front area.

– Fold the boot with the center console frame up over the shifter

knob.

– Open the clamp -arrow- and remove the shift knob and boot.

In some equipment versions, the center console frame remains

in the center console.

– It may be necessary to pull or pry the center console frame out

carefully.

– Remove the noise insulation -1-.

Installing

– Install the noise insulation.

Installation Location, Noise Insulation

•

-Arrow A- points in direction of travel.

The tabs -arrows B- must latch into the center console.

– Press the center console frame into the center console, if nec‐

essary.

– Then turn inner side of boot toward outside.

Install the shift knob all the way on.

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the shifter knob with frame and boot and press the new

clamp -arrow- together.

– Press the boot with the frame into the center console or the

boot into the frame.

1.5

Overview - Gearshift Lever and Gearshift Housing, through 10/2006

Note

Lubricate bearing areas and slide surfaces with Grease - G 000 450 02- .

1 - Lock Washer

❑ Removing and instal‐

ling. Refer to

⇒ Fig. ““Removing and

Installing the Lock

Washer”“ , page 83 .

2 - Bushing

3 - Pressure Spring

4 - Bushing

®

5 - TORX Bolt

❑ 5 Nm

6 - Cover

7 - Insulation

8 - Insulation

9 - Bearing Shell

10 - Gearshift Lever Guide

11 - Washer

12 - Seal

❑ Between the gearshift

housing and the under‐

body

❑ Self-adhesive

❑ Affix to the gearshift

housing

13 - Gearshift Lever

14 - Gearshift Housing

15 - Bearing Bushing

16 - Mounting Pin

17 - Guide Bushing

18 - Pressure Spring

❑ Installing. Refer to ⇒ Fig. ““Installing the Pressure Spring”“ , page 83 .

1. Shift Mechanism, Servicing

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6-Speed Manual Transmission 02Q - Edition 05.2013

19 - Selector Bracket

®

20 - TORX Bolt

❑ 5 Nm

21 - Seal

❑ Replace after removing

22 - Base Plate

❑ Bend the tabs in order to remove

❑ Replace after removing

23 - Selector Cable

❑ To the selector bracket

❑ Removing and installing. Refer to

⇒ Fig. ““Detaching from the Selector Cable and the Shift Cable and Attaching”“ , page 82 .

24 - Gearshift Cable

❑ Removing from the shift lever guide and attaching to the shift lever guide. Refer to

⇒ Fig. ““Detaching from the Selector Cable and the Shift Cable and Attaching”“ , page 82

25 - Lock Washer

❑ Replace after removing

26 - Nut

❑ M6: 8 Nm

❑ M8: 25 Nm

❑ Quantity: 4

27 - Bearing Bushing

❑ Fits in one position only

28 - Lock Washer

❑ Replace after removing

Detaching from the Selector Cable and the Shift Cable and At‐

taching

– Remove the lock washer from the shift cable -A- and the se‐

lector cable -B-.

Lift the tab with a screwdriver in direction of -arrow 1- and remove

the lock washer in direction of -arrow 2-.

– Remove the shift cable -A- from the gearshift lever mount.

– Remove the selector cable -B- from the selector bracket

mount.

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

6-Speed Manual Transmission 02Q - Edition 05.2013

Removing and Installing the Lock Washer

– Push the bushing -arrow B- all the way in direction of

-arrow C- and remove or install the lock washer -arrow A-.

Note

♦ Do not tilt the bushing when pushing it down.

♦ The slot in the lever for the circlip must be visible.

♦ Carefully release the tension on the spring.

Installing the Pressure Spring

– Install the compression spring so that the brace -A- contacts

upper part of pin -arrow-.

– Pull the brace -B- downward so that it reached the bottom of

the pin -arrow-.

1.6

Overview - Gearshift Lever and Gearshift Housing, from 11/2006

Note

♦ Lubricate the bearing areas and the sliding surfaces.

♦ Refer to the Parts Catalog for the grease allocation.

♦ Gearshift mechanism, disassembling and assembling. Refer to

⇒ “1.12 Selector Mechanism, Disassembling and Assembling, from 11/2006”, page 100 .

1. Shift Mechanism, Servicing

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6-Speed Manual Transmission 02Q - Edition 05.2013

1 - Base Plate

❑ Bend the tabs in order to

remove

❑ Replace after removing

2 - Seal

❑ Replace after removing

3 - Gearshift Lever

❑ Can be removed and in‐

stalled with the shift lev‐

er guide installed

-item 15-

⇒ Item 15 (page 84) .

4 - Washer

❑ Slide out of shift lever as

far as stop -arrow-.

5 - Lock Washer

❑ Be careful not to dam‐

age the cables when re‐

moving them

❑ Replace after removing

6 - Selector Cable

❑ Pry off of selector brack‐

et

❑ Press onto selector

bracket inside the shift

mechanism

❑ Installation position. Re‐

fer to

⇒ “1.1 Shift Mechanism

Installation Position”,

page 76 .

7 - Bushing

8 - Gearshift Cable

❑ Pry off of shift lever guide

❑ Press onto shift lever guide inside the shift mechanism

❑ Installation position. Refer to ⇒ “1.1 Shift Mechanism Installation Position”, page 76 .

9 - Insulation

10 - Bearing Shell

❑ Will get damaged when being removed

❑ Replace after removing

11 - Bushing

12 - Lock Washer

❑ Removing and installing. Refer to ⇒ Fig. ““Removing and Installing the Lock Washer”“ , page 83 .

13 - Pressure Spring

❑ Removing and installing. Refer to ⇒ Fig. ““Removing and Installing the Lock Washer”“ , page 83 .

14 - Bushing

15 - Gearshift Lever Guide

16 - Nut

❑ M6: 8 Nm

❑ M8: 25 Nm

❑ Quantity: 4

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Rep. Gr.34 - Operation and Housing

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6-Speed Manual Transmission 02Q - Edition 05.2013

17 - Seal

❑ Between the gearshift housing and the underbody

❑ Self-adhesive

❑ Affix to the gearshift housing

18 - Gearshift Housing

❑ With spring and selector bracket

❑ Spring and selector bracket cannot be removed

1.7

Overview - Operating Cables

Note

Lubricate the bearing areas and the sliding surfaces. Refer to the Parts Catalog for the grease allocation.

1 - Gearshift Cable

❑ Attach to the cable re‐

tainer -item 18-

⇒ Item 18 (page 87) .

❑ Installation position. Re‐

fer to

⇒ “1.1 Shift Mechanism

Installation Position”,

page 76 .

❑ From 11/2006 changed

fastener on shift lever in‐

side shift mechanism

-item 8-

⇒ Item 8 (page 84)

2 - Selector Cable

❑ Attach to the cable re‐

tainer -item 11-

⇒ Item 11 (page 86) .

❑ Installation position. Re‐

fer to

⇒ “1.1 Shift Mechanism

Installation Position”,

page 76 .

❑ From 11/2006 changed

fastener on selector

bracket inside shift

mechanism -item 6-

⇒ Item 6 (page 84)

3 - Lock Washer

❑ Replace after removing

❑ Discontinued on gear‐

shift mechanisms from

11/2006. Refer to

⇒ “1.6 Overview - Gear‐

shift Lever and Gear‐

shift Housing, from

11/2006”, page 83

4 - Lock Washer

❑ Be careful not to damage the cables when removing them

❑ Replace after removing

1. Shift Mechanism, Servicing

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6-Speed Manual Transmission 02Q - Edition 05.2013

5 - Gearshift Housing

6 - Hex Bolt

❑ 20 Nm

❑ For the cable bracket

❑ Quantity: 2

7 - Cable Bracket

❑ Can be made of plastic or metal

8 - Grommet

❑ Cable mounting bracket to transmission

9 - Spacer

10 - Nut

❑ 20 Nm

❑ For the cable bracket

11 - Cable Retainer

❑ For attaching the selector cable to the relay lever

❑ Adjust the gearshift mechanism after installing. Refer to

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

❑ Do not interchange, cable locking mechanisms for selector cable on linkage lever and for shift cable on

transmission shift lever are different. Refer to ⇒ Fig. ““Cable Retainer Allocation”“ , page 87 .

❑ From 05/2007 installed in with the plastic relay lever. Refer to ⇒ “1.8 Plastic Relay Lever”, page 89 .

❑ Removing from plastic relay lever. Refer to ⇒ “1.8 Plastic Relay Lever”, page 89

❑ Installing on plastic relay lever. Refer to ⇒ “1.8 Plastic Relay Lever”, page 89

❑ Allocation. Refer to ⇒ Fig. ““Cable Retainer Allocation”“ , page 87 .

12 - Relay Lever

❑ Installation position. Refer to ⇒ Fig. ““Selector Lever/Relay Lever Installed Position”“ , page 88 .

❑ Adjust the gearshift mechanism after installing. Refer to

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

❑ Can be made of plastic or metal

❑ The metal relay lever is placed in the bushings -item 13- ⇒ Item 13 (page 86) and secured with a lock

washer -item 14- ⇒ Item 14 (page 86) .

❑ From 05/2007 plastic relay lever

❑ Plastic relay lever, removing and installing with cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89

❑ The bushings and lock washers are not needed with the plastic relay lever

13 - Bearing Bushing

❑ Discontinued on the plastic relay lever

14 - Lock Washer

❑ Replace after removing

❑ Discontinued on the plastic relay lever

15 - Sliding Shoe

16 - Selector Lever

❑ With a balance weight

❑ Insert so that master spline aligns with shift rod

❑ Adjust the gearshift mechanism after installing. Refer to

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

❑ Installation position. Refer to ⇒ Fig. ““Selector Lever/Relay Lever Installed Position”“ , page 88 .

❑ From 06/2006 the cable retainer mounting pin has a smaller diameter. Refer to

⇒ Fig. ““As of 06/2006, Smaller Bolt Diameter for the Shift Cable Retainer.”“ , page 87

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

17 - Hex Nut

❑ 23 Nm

❑ Self-locking

❑ Replace after removing

18 - Cable Retainer

❑ For attaching the shift cable to the transmission shift lever

❑ Adjust the gearshift mechanism after installing. Refer to

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

❑ Do not interchange, cable locking mechanisms for selector cable on linkage lever and for shift cable on

transmission shift lever are different. Refer to ⇒ Fig. ““Cable Retainer Allocation”“ , page 87 .

Cable Retainer Allocation

These holes have different diameters.

Cable Retainer For:

Dimension “a”

8.5 mm

1. - Gearshift cable to gearshift lever from

06/2006

2. - Gearshift cable to gearshift lever to 05/2006

2. - Selector cable to metal relay lever

10 mm

8 mm

2. - Selector cable to plastic relay lever. Refer to

10 mm

⇒ “1.8 Plastic Relay Lever”, page 89

As of 06/2006, Smaller Bolt Diameter for the Shift Cable Retainer.

Mounting Pin for Gearshift Cable Retainer

Through 05/2006

Dimension “a”

10 mm

From 06/2006

8.5 mm

1. Shift Mechanism, Servicing

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6-Speed Manual Transmission 02Q - Edition 05.2013

Installing the Transmission Shift Lever

– When positioning the transmission shift lever, make sure the

gap -arrow A- is placed over the missing selector shaft teeth

-arrow B-.

Selector Lever/Relay Lever Installed Position

1 - Gearshift lever with balance weight

2 - The relay lever grips into the sliding rail on the gearshift lever

via the sliding shoe -arrow-.

Cable Retainer, Replacing

– Pull the securing mechanism forward at the cable retainer from

the shift cable and selector cable as far as the stop in direction

of -1 arrows- and then release it to the left in direction of

-2 arrows-.

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Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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.

Plastic Relay Lever

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

⇒ “1.8 Plastic Relay Lever”, page 89 .

– Pry the cable retainer out. Refer to

⇒ Fig. ““Removing the Selector Cable Retainer from the Plas‐

tic Relay Lever.”“ , page 92 .

Continuation for All Shift Mechanisms

– 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.

– Attach the shift cable with lock washer -3- (metal relay lever)

and selector cable with lock washer -4-.

Note

If a plastic relay lever is installed, it must be installed together with

the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89 .

– Adjust the gearshift mechanism. Refer to

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

1.8

Plastic Relay Lever

A plastic relay lever is installed from 05/2007. Two versions may

be installed.

♦ Relay lever with tab or

♦ Relay lever with clip

Note the following when removing and installing:

•

To remove the relay lever, it is necessary to remove the cable

retainer from the selector cable.

This prevents damage to the selector cable.

– 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-).

1. Shift Mechanism, Servicing

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6-Speed Manual Transmission 02Q - Edition 05.2013

Relay Lever with Tab -arrow 1-

– Press the tab -arrow 1- down as far as the stop and remove

the relay lever together with the cable retainer. Move it in the

operating direction when doing so.

Relay Lever with Clip -arrow 1-.

– Remove the clip -arrow 1- and the relay lever together with the

cable retainer.

Continuation for All

•

The cable retainer must be behind the catch -arrow 2-.

The cable retainer may only be removed with the relay lever

removed. Refer to

⇒ Fig. ““Removing the Selector Cable Retainer from the Plas‐

tic Relay Lever.”“ , page 92 .

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Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

Note

♦ For installing, lubricate the following areas very carefully.

♦ Relay lever shaft -A- in direction of -arrows-.

♦ Gearshift lever glide track -B-, fits into the relay lever.

♦ The relay lever and gearshift lever in the illustration may differ

from the original part.

♦ Refer to the Parts Catalog for the grease allocation.

– Press the cable retainer on the relay lever. Refer to

⇒ Fig. ““Installing the Cable Retainer”“ , page 92 .

– Insert the relay lever together with the cable retainer as far as

the stop.

Relay Lever with Tab -arrow 1-

•

The catch -arrow 1- secures the relay lever.

Make sure it engages securely.

The cable retainer must be behind the catch -arrow 2-.

Relay Lever with Clip -arrow 1-.

•

The clip -arrow 1- secures the relay lever.

Make sure the clips locks securely.

The cable retainer must be behind the catch -arrow 2-.

1. Shift Mechanism, Servicing

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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.

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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

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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) .

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Rep. Gr.34 - Operation and Housing

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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

to

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

and Installing”, page 79 .

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– 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.

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Release the retainers -A- for the shift and selector cables -B- as

follows:

♦ Push the sleeve forward as far as it will go in direction of

-arrow 1-.

♦ Turn the sleeve to the right as far as it will go in direction of

-arrow 2- until it engages.

– Remove the retainers from the cables.

– Remove the lock washers -1 and 2-.

– Remove the cable bracket from the cables.

Installing

Install in reverse order of removal while. Note the following:

– Secure the shift cable and selector cable on the shift housing

with lock washers -2 and 3-.

– Attach the shift cable and the selector cable to the gearshift

lever and the selector lever inside the shift housing and secure

it with lock washers -1 and 4-.

Note

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

nisms beginning in 11/2006.

– Install the base plate with a new seal on the gearshift housing

-arrows-. Refer to

⇒ Fig. ““Base Plate, Attaching to Gearshift Housing”“ ,

page 105 .

– Install the gearshift mechanism. Refer to ⇒ page 94 .

– Adjust the gearshift mechanism. Refer to

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

1.11

Selector Mechanism, Adjusting

Connecting Pin - T10027A-

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Note

♦ The following is important to make sure the gearshift adjust‐

ment is correct:

♦ Operating and transfer elements of shift mechanism must be

in proper condition.

♦ Shift mechanism must move freely.

♦ The transmission, clutch and clutch mechanism must also be

in proper condition.

•

Transmission in neutral.

– Remove the entire air filter housing if the bracket -A- for the

selector shaft and the securing mechanism for the shift and

selector cables are not accessible through it. 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 .

– Pull the safety mechanism on the cable retainer for the shift

cable and the selector cable all the way forward in direction of

-arrow 1- and then lock it to the left in direction of -arrow 2-.

Hold the gearshift shaft secure as follows:

– Push the gearshift shaft in direction of -arrow 1-.

– While pressing down selector shaft, rotate lock bolt -A- upward

in direction of -arrow 3- and simultaneously press it in direction

of -arrow 2- until it engages in selector shaft.

– Remove the boot with the shifter knob and frame. Refer to

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

and Installing”, page 79 .

– If equipped, remove the noise insulation.

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Hold the gearshift shaft secure as follows:

– Move the gearshift lever into neutral.

– Guide the Connecting Pin - T10027A- through the hole -A- and

into the hole -B-.

– Make sure the selector and shift cable -B- are inserted into the

retainer -A- without tension.

– Turn the locking mechanism on the shift cable retainer and the

selector shaft all the way to the right in direction of -arrow 1-.

The spring will push the safety mechanism into the starting posi‐

tion in direction of -arrow 2-.

– Turn the bracket -A- back into the starting position -arrow 2-.

•

The bracket -A- must get pushed out of the transmission in

direction of -arrow 1-.

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– Pull the Connecting Pin - T10027A- out of the holes

-A and B-.

– If equipped, install the noise insulation.

– Install the boot, the gearshift knob and the frame. Refer to

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

and Installing”, page 79 .

– Make sure the gearshift shaft moves easily.

– 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 .

Function

•

The shift lever must rest in the 3rd/4th gear selector lever gate

when the transmission is in neutral.

– Operate the clutch.

– Move the gearshift lever (selector lever) several times through

all the gears. Pay particular attention to the operation of the

reverse gear lock.

– Should a gear fail to engage smoothly after repeated selection,

adjust the gearshift mechanism again. Refer to

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

1.12

Selector Mechanism, Disassembling

and Assembling, from 11/2006

Special tools and workshop equipment required

♦ Window Release Tool - T10236-

♦ Press Piece - Multiple Use - VW412-

♦ Over-Center Spring Assembly Tool - T10178- or flat iron, 200

x 25 x 5 mm

♦ Engine Support Bridge - Engine Support 25 - 10-222A/25- or

flat iron, 350 X 30 X 5 mm

♦ - 4- = Puller - Counterstay , for example -Kukko 22/4-

♦ Wedge - T10357-

♦ Press Piece - Block - T10083-

♦ Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

Disassembling

– Remove gearshift mechanism. Refer to

⇒ “1.9 Selector Mechanism, Removing and Installing”,

page 92 .

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– Bend up the selector mechanism base plate straps -arrows-

with a screwdriver and remove the base plate. Only the straps

on the left side of the base plate are shown in the illustration.

– Remove seal from shift housing.

– Remove shift cable and selector cable from selector housing.

Refer to ⇒ “1.7 Overview - Operating Cables”, page 85 .

– Raise upper side of spring -A- over selector bracket tab.

– Using a screwdriver, press bearing shell notches -arrows- in

direction of shift lever guide bearing; break off notches if nec‐

essary.

– Pry out bearing shell -A- with shift lever guide -B- from selector

housing.

– Then press bearing shell off shift lever guide bearing and re‐

move.

•

Observe guides -A- in subsequent steps.

They must not break off.

– Raise lower side in direction of -arrow 1- of spring as far as

stop onto shoulder on selector bracket.

– Now raise shift lever guide up as far as stop and remove ball

studs from selector bracket in direction of -arrow 2-.

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– Turn the gearshift lever in the direction of -arrow 1-.

•

The pins -arrow 2- must be in the shift housing opening.

– Move the gearshift lever guide and the gearshift lever in the

direction of -arrow 3-.

Assembling

Caution

The lower side of the spring in direction of -arrow 1 -can spring

down uncontrolled from the selector bracket shoulder during

subsequent handling.

– Carefully press it down from the selector bracket shoulder.

The spring sides then twist “diagonally” with a loud noise.

– Turn both springs to the right and release the tension on the

ends -A and B-.

•

The ends -A and B- must face in the opposite direction.

Note

The selector shaft must be removed in order to insert the shifter

housing with the selector shaft guide into the Pressing Support .

– Install the shift lever guide into the shift housing.

•

The pins -arrow 1- are still located in the shift housing opening.

– Turn the gearshift lever guide in the direction of -arrow 2- until

the ball head pin -A- is above the opening in the gearshift

housing.

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– Install the gearshift housing with gearshift lever guide into the

larger depression -arrow- in the Press Piece - Block - T10083- .

Note

The selector shaft must be removed in order to insert the shifter

housing with the selector shaft guide into the Pressing Support .

•

The shift lever guide must project out of selector housing as

far as stop.

Note

The selector bracket is only partially shown to provide a better

illustration.

– Insert spring side -A- from above into guide.

– Pull spring side -B- down and insert it near the guide (in di‐

rection of ball head).

– Carefully remove the gearshift housing with the shift lever

guide from the Press Piece - Block - T10083- .

– Move selector bracket back as far as stop (opposite mounting

holes for shifter and selector cable) in direction of -arrow 1-.

– Lubricate ball head pins.

– Press ball head pins into selector bracket -arrow 2-.

•

The guides -A- and the tabs -B- must not be damaged.

– Install the gearshift housing with gearshift lever guide into the

larger depression -arrow- in the Press Piece - Block - T10083- .

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•

The shift lever guide must project out of selector housing as

far as stop.

– Raise upper side of spring -A- over selector bracket pins.

Use a new bearing shell -B-.

•

– Lubricate bearing shell and shift lever guide bearing.

– Press bearing shell onto shift lever guide bearing as far as

stop.

– Remove selector mechanism from Press Piece - Block -

T10083- .

– Insert lower side -C- of spring into guide.

– Raise upper side of spring -A- over selector bracket pins into

guide.

– Press bearing shell into selector housing -arrows-.

•

All four retaining tabs must engage.

– If equipped install the shift lever in the shift housing.

– Secure the shift cable and selector cable on the shift housing

with lock washers -2 and 3-.

– Install the shift cable -1- on the gearshift lever and selector

cable -4- on the selector lever inside the shift housing.

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Base Plate, Attaching to Gearshift Housing

– Install a new seal -item 2- ⇒ Item 2 (page 84) on the base plate.

Caution

There is a danger of causing damage to the gearshift housing

and base plate.

Tension the gearshift housing only slightly.

– Bend the tabs -arrow- back over all around the base plate to

secure it (only the tabs on the left side of the base plate are

shown in the illustration).

Note

♦ If only one Over-Center Spring Assembly Tool - T10178- is

available, instead of a second Over-Center Spring Assembly

Tool - T10178- the Toothed Belt Tensioner - T10020- can be

used.

♦ A 200 x 25 x 5 mm flat iron can be used in place of an Over-

Center Spring Assembly Tool - T10178- .

♦ A 350 X 30 X 5 mm flat iron can be used in place of an Engine

Support Bridge - Engine Support 25 - 10-222A/25- .

– The tabs can be bent back over using the Wedge - T10357- .

- A- = Puller - Counterstay , for example -22/4-

– Glue a new seal on the gearshift housing .

– Install the gearshift mechanism. Refer to

⇒ “1.9 Selector Mechanism, Removing and Installing”,

page 92 .

1. Shift Mechanism, Servicing

105

OperationandHousing -> 1 Shift Mechanism, Servicing for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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