Controls, Housing
Repairing shift linkage
(Side pressure system)
Golf
Up
to November 1974
(Chassis No. 175 3168 641)
Scirocco
Up
to November 1974
(Chassis No. 535 2019 465)
Caution
All connections must fit together easily.
There must be no sticking or jamming due to straining of linkage in mountings.
Caution
Lubricate all joints and friction surfaces with MoS grease
Connecting link
o Between
relay shaft
and selector
shaft lever.
o The end bent
exactly at
right angles
goes on the
relay shaft.
Relay shaft
Relay lever
Bearing plate
o Adjust by
engaging 1st
gear and
moving
plate until
selector
lever is
vertical.
Shift rod
Selector lever
Bell crank
Bearing rod
o Adjust
=> Fig. 2
Selector rod
adjustable
o Adjust
=> Fig. 3
Caution
Lubricate all joint and
friction surfaces with
MoS grease.
Gear lever
o Adjust
=> Fig. 1
Bearing shell
upper
o must fit
properly
into
lower
shell
Shift rod
Lever, plate
lower
o Need not
be
removed
to take
lever out
Lever plate
upper
o Adjust
=> Fig. 1
o The
pointed
slot must
be at the
front
Fig. 2
rod
Adjusting bearing
Fig. 3
rod
Adjusting selector
Controls, Housing
Adjusting gear shift linkage
(Downward pressure system)
Align centering
holes -arrows- in lever
plate and housing cover
plate.
Note:
The tapped holes for the bolts
should now be in the centre of
the slots -arrow-. If they are not,
turn the lever plate 180.
Note:
If gearshift still sticks or is
spongy after correct adjustment,
adjust the retaining screw
Adjusting selector shaft
retaining screw
When gearbox has been
dismantled or if gearshift jams
or is spongy, the retaining screw
should be adjusted.
From
The bushes riveted in the bearing plate now have larger grease pockets. The protective boots
have been discontinued.
12bearing
3456-
Relay lever
Shift rod
Shift rod
Clamp
Selector rod
Selector lever
1 - 4 speed
gearbox: Press selector
rod on at botton
2 - 5 speed
gearbox: Press selector
lever on at top
ype of grease
As with all other passenger car shift linkages, the linkage of this 4 speed gearbox is in future
to be lubricated with
Special lubricating paste white - Part No. AOS 126 000 05
Up to December 1975
Removing
Press bushes out
Installing
Press bushes in
flush.
Installing
1 - Disconnect
battery earth cable
2 - Install and
tension lifting appliance
3 - Detach left
gearbox mounting
4 - Remove
TDC sender unit with a
spark plug spanner (part
No. 311 012 205 A) and
turn engine with V belt
until the lug on the
flywheel (33 before
TDC) appears in the
TDC sender unit hole.
Note:
The engine and gearbox can
only be separated whit flywheel
in this position.
On vehicles with 81 KW engine
the drive flange on engine side
has a flat on it. To separate
engine and gearbox, position flat
towards flywheel.
5 - Disconnect
speedo cable and seal
hole with a rubber cap to
prevent oil from running
Modification
9 - Disconnect
linkage from selector
shaft.
10 - Take relay
lever off bearing rod.
11 - Detach
earth wire from gearbox.
12 - Remove
starter.
13 - Detach torque
strut from gearbox and
body.
14 - Detach rear
gearbox mounting
15 - Detach left
drive shaft and hang up
on a wire hook.
16 - Detach
right drive shaft and
hang up on a wire hook.
17 - Remove
screws securing large
cover plate. Plate stays
on engine.
18 - Remove screw
securing small cover
plate and take plate off.
19 - Remove nut or
bolt.
Press
gearbox off
dowel sleeves and take it
out downwards. (Two
mechanics required).
Installing
- 75
Nm
- 45
Nm
- 45
Nm
- 40
Nm
- 15
Nm
Remove
selector shaft
and install 020 301 235
(or shaft from old box).
Install retaining screw
020 301 241 A and
Gearbox
housing
o
Repai
ring =>
page
34-40
Sleeve
Release bearing
15 Nm
End cover
Gasket
Plug
Nut
o
15 Nm
(3 off)
Screw
o
Secures
reverse
shaft 20
Nm
Clutch lever
o Onl
y fits
one
way on
release
shaft
o Mod
..
Return spring
Locking ring
o Mod
.
=>page
34-56
Release shaft
Oil deflector
End cover
o Mod
.
=>page
34-52
Spring large
o Presses
selecto
r shaft
lever
into
3/4
gear
plane
Spring small
o Only
for
side
pressur
e
system
(up to
Aug.
75)
Selector shaft
Mod
.,
o
Sele
ctor
shaft
cover
modifi
ed =>
page
34-59
Reversing light
switch
o Mod.
=> page
34-54
Clamping bolts
o (3 off)
Output shaft
gears
o Remo
ving and
installing
drive
shaft,
output
shaft and
differenti
al
Shim
o
See
list on
=> page
39-20
M 8 x 35 bolt
(2 off)
install
below
the
locking
screw for
selector
shaft. 25
Nm.
Locking screw
for select shaft
o Adjust
=> page
34-17
o 20 Nm
Gasket
o
Shape
altered
from 07
08 5,
renew
M 8 x 50 bolt
o (12
off),
25 Nm
Drive flange
Dished
washer
Circlip
o
Ren
ew,
must
fit
proper
ly in
the
groove
.
Cap
o
o
Ren
ew
Torqu
e
25Nm
Note:
Vehicles
with 81 KW
engine:
Use only
expansion
bolts to secure
gearbox and
bearing
housings.
Torque 25
Nm
Up
to 14 12
6 - Renew
gearbox and
bearing
housing bolts.
Installing gearbox in
repair stand - VW.
Pull
Installing gearbox in
repair stand - Audi.
clutch rod out
downwards.
A - Locknut M 12.
Lift
A - Locknut M 12.
VW 295a into
contact with drive shaft
with screw and lock.
Screw two M 8 x 30
bolts through slots into
flange.
shaft.
Take off release shaft ,
clutch lever, return
spring, release bearing
and sleeve.
Remove selector
shaft end plug.
Move selector
forks to
neutral and pull selector
shaft out.
Note:
If the selector forks cannot be
placed in neutral the selector
shaft cannot be pulled out. Shaft
can then be removed by force as
follows:
Remove bolts
attaching gearbox
housing.
Pull housing off.
A - Screws two M 7 x 30
bolts (N 10 407.1)
through the holes into
the housing.
Installing
If drive shaft has not been
dismantled, press drive shaft ball
bearing off ; Fig.1 .
Insert clamping
bolts and tighten nuts.
a - Screw two M 8
studs into bearing
housing to guide gearbox
housing.
b - Ensure that the
drive shaft is properly
supported by bar 30-211
and adaptor VW 295 A.
Knock housing on.
Screw in bolt securing
Modifications
Gearbox housing/end cover
From Assembly date 15 03 5:
The bore in the housing for the
end cover was changed form
tapered to cylindrical.
Repair instructions
(Gearbox up to 14 03 5)
When fitting a new gearbox
housing use 020 301 051 A
housing,end cover 020 301 232
A and boot 020 301 261 A.
Selector shaft
Up to Assembly date 24 08 5:
Side pressure system.
Reverse catch provided by
chamfer on selector shaft arrow- and retaining screw.
Clutch lever
From 15 03 5 to 16 03 7
Lever with shoulder -1-,
secured with one circlip -2-.
Modification
From Assembly date 07 05 4
Level checking hole
discontinued. Oil is put in and
checked through the filler hole.
Part No.
020 300 044 F
171 711 141 E
171 711 261 C
171 711 163 B
171 711 574 B
171 711 593 E
171 711 177 C
171 399 113 H
171 711 195 C
171 711 210
171 711 229 A
this case it is necesary to ensure that there sufficient clearance between wheel housing and
wheel in all supension positions and on all wheel locks.
The service installation in vehicles with 51 kw (70 bhp) and 55 kw (75 bhp) is not
contemplated due to the different engine characteristics.