Controls, Housing

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

Selector shaft lever

o Only fits

shaft in one

position.

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 shaft bracket

Relay lever

Bearing plate

o Adjust by engaging 1st

gear and

moving

plate until

selector

lever is

vertical.

Shift rod

Square head bolt

o Remove and install

with VW

114 lock

with wire.

Selector lever

Selector rod with

ball joint

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

Adjusting shift linkage

(Side pressure system)

Fig.1 Adjusting gear lever

Loosen bolts and move upper

plate until lower part of lever is

vertical in neutral. If necessary,

move cover plate in elongated

holes.

Fig. 2 Adjusting bearing rod

(Only up to November 1974)

a = 31 1 mm.

The rod must no jam in the

bushes.

Note:

If gearshift still sticks or is

spongy after correct adjustment,

adjust the retaining screw .

Fig. 3 Adjusting selector rod

(Only up to November 1974)

b = 164 1 mm.

Controls, Housing

Adjusting gear shift linkage

(Downward pressure system)

Place lever in neutral.

Lever plate position

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.

Secure the lever bearing.

Loosen the clip. The

selector lever must move

easily on the shift rod.

Pull the large boot off

the lever housing and

push it along the shift

rod. It may be necessary

to loosen the screws in

the housing cover plate

to free the boot.

Locate the shift finger -1- in the centre of

the stop plate -2-

The distances x must be the

same.

Set distance "a". With a 20 mm wide strip

of sheet metal.

Tighten clip in this

position.

Select all gears in turn

and check that they

engage easily and

without catching. Ensure

that reverse catch is

effective

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.

Adjust with gearbox out or

disconnect linkage from selector

shaft lever and place fox in

neutral

Note:

There are two different screws

Side pressure system

Shoulder =>arrow

Downward pressure system

A - Vehicles up to December

1974

(Side pressure system)

Turn slotted screw -1- in until it makes

contact.

Watch nut -2- while

turning screw (it starts to

move outwards when

contact is mode)

From this position, turn

slotted screw out 1/4 of a

turn and fit plastic cap

Renewing retaining screw

Install Part No. 020 301 241 A

and adjust as described at "B".

B - Vehicles from January to

August 1975

(Side Pressure system)

Turn locknut -2- back and retaining screw

-1- in.

Press selector shaft -4-

in until it contacts

reverse gear catch.

Turn retaining screw

out slowly until selector

shaft jumps out under

spring pressure and then

turn screw out 1/4 of a

turn further.

Lock screw in this

position.

C - Vehicles from September

1975

(On downward pressure system

only)

Loosen locknut -2- and turn retaining screw

-1- in until locking clip -

4- lifts off retaining

screw.

Turn retaining screw

back again until clip just

makes contact.

Tighten locknut.

Check: The clip should

lift as soon as shaft -3- is

turned slightly.

Modifications to the shift linkage

The parts listed below have been take over from the shift linkage of the 5 speed manual

gearbox. They will in future be the same for both gearboxes.

1. Boot with cap from April 1981

2. One-piece shift rod bearing from August 1980

3. Relay lever with larger rubber ball from February 1982

4. Type of grease

Boot with cap

Only the cap need be removed to make adjustments. The boot can be left in position.

One-piece shift rod bearing

The bushes riveted in the bearing plate now have larger grease pockets. The protective boots

have been discontinued.

1 - Relay lever

2 - Shift rod

bearing

3 - Shift rod

4 - Clamp

5 - Selector rod

6 - Selector lever

Relay lever with larger rubber ball

The hole in the selector lever

has been altered to match the

larger rubber ball (30 mm

instead of 24 mm).

The selector lever for 4 and 5

speed gearboxes are thus the

same apart from the position of

the welded--in ball stud. As a

service part, a selector lever

with two welded-in ball studs is

supplied which can be used for 4

and 5 speed gearboxes.

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

Removing and installing bonded rubber bushes for gearbox carrier

(Gearbox in)

Up to December 1975

Removing

Press bushes out

Installing

Press bushes in flush.

Install bush so that -arrow- points upwards

with carrier installed.

From January 1976

Removing

Cut the metal outer shell with a narrow

hacksaw blade to reduce

tension and knock bush

out.

Installing

Press bush in flush

Removing and installing gearbox

Service installation of the 5 speed manual gearbox .

Removing

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

out when engine is taken

out.

6 - Remove upper

bolts attaching gearbox

to engine

7 - Pull reversing

light wire off

8 - Disconnect

clutch cable

Modification

From 9/74 (Except 81 KW

engine)

Depression 76 before TDC instead of lug 33 before TDC

(3 recesses on flywheel instead

of 2, => page 34-34 ).

Mod.:

From 11.78 securing point 18

changed from stud and nut to

bolt (M 12 x 58). At the same

time the recess ( => page 34-34 )

and the lug 76 before TDC in

flywheel, were discontinued.

When removing gearbox, turn it

until there is sufficient clearance

between flywheel and drive

flange. Its is no longer necessary

to align flywheel or flange.

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

Install by reversing the removal sequence

=> Repair Group 10; Engine

Caution

The recess in the flywheel must

be positioned level with the

drive flange -arrow-.

Tightening torques:

Gearbox to engine

(M 12)

- 75

Nm

Gearbox to engine

(M 10)

- 45

Nm

Drive shaft to flange - 45

Nm

Left mounting to

gearbox

- 40

Nm

Shift rod to linkage - 15

Nm

When gearbox has been

installed, check length of

selector rod (b) and adjust if

necessary => page 34-8

Renewing gearbox

From assembly date 07 085 to

24 085, gearboxes with high-

mounted starter and side

pressure shift system where

installed. When renewing, use

Port No. 020 300 043 B - for

downward pressure system (

without reverse catch).

This box must be converted to

side pressure system as follows:

Remove selector shaft

and install 020 301 235

(or shaft from old box).

Install retaining screw

020 301 241 A and

adjust as detailed on =>

page 34-17 , under B.

This conversion is essential as

otherwise there is no reverse

catch.

Dismantling and assembling gearbox

Repair and adjustment

of the clutch and clutch

linkage .

Removing and

installing housing

Gearbox

housing

o Repairing =>

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 Only 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

o Mod. ,

o Selector

shaft

cover

modifi

ed =>

page

34-59

Reversing light

switch

o Mod. => page

34-54

Clamping bolts

o (3 off)

Clutch push rod

o Grease at

bush in

drive

shaft

(multipur

pose

grease)

Output shaft

gears

o Removing and

installing

drive

shaft,

output

shaft and

differenti

al

Shim

o See list on

=> page

39-20

M 8 x 35 bolt

o (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 Renew,

must

fit

proper

ly in

the

groove

.

Cap

o Renew

o 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.

Removing and installing Housing

Removing

Installing gearbox in repair stand - VW.

Installing gearbox in repair stand - Audi.

Pull clutch rod out

downwards.

Fitting support bar for drive shaft - VW

A - Locknut M 12.

Lift VW 295a into

contact with drive shaft

with screw and lock.

Fitting support bar for drive shaft - Audi.

A - Locknut M 12.

Remove cap, circlip and washer from drive

flange.

Pull flange off.

Screw two M 8 x 30

bolts through slots into

flange.

Take cover off.

Lever circlip off release

shaft.

Take off release shaft ,

clutch lever, return

spring, release bearing

and sleeve.

Lever plugs -arrows- out and take off

3 nuts.

Remove selector shaft

retaining screw.

Remove bolt securing

reverse gear shaft.

Screw reversing light

switch out.

Remove selector shaft end plug.

A - Spark plug spanner

(Part No. 311 012 205

A).

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:

Take circlip -2- off (only on downward

pressure system).

Knock shaft -1- out.

Sheet metal housing -3-

, shift finger -4- and

sleeve -5- remain in

housing -6-.

If 1st, 2nd or reverse

gear are engaged.

When knocking shaft

out, place a nut between

sheet metal housing -3-

and gearbox -6- as a

support -arrow-

Renew damaged parts

(selector shaft, shaft,

selector forks).

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 .

Press drive shaft bearing into housing

with shims in position.

Insert clamping bolts and tighten nuts.

Align reverse gear shaft. Spacing x must be

the same.

Before Knocking housing on:

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

reverse gear shaft.

Screw in bolts securing

housing.

Move forks to neutral,

insert selector shaft and

install cover.

Install reversing light

switch.

Install and adjust

retaining screw for

selector shaft => page

34-17

Install drive flange. Fit washer and circlip

Press drive flange circlip into position.

Install cap.

Retighten nuts on

clamping bolts to 1.5

mkg and fit plugs.

Install drive shaft circlip

Install release bearing

and sleeve. Fit release

shaft, clutch lever and

return spring. The bent

ends of the spring

contact the housing wall

and the centre part hooks

on to the clutch lever.

Install locking ring (s) for release shaft.

Fit cover and insert

clutch rod.

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.

From Assembly date 25 08 5:

Downward pressure system.

Reverse catch moved to shift linkage. Chamfer on selector

shaft discontinued, retaining

screw modified, spring at end of

shaft dropped.

Reversing light switch

From Assembly date 07 08 5.

The switch is mounted on a bracket -1- attached to the

gearbox and operated by the

selector shaft lever -2-.

Adjust or bend the bracket so

that the reversing lights work

properly.

From Assembly date 05 04 6.

The switch is in the gearbox again.

Operated by a lug on the reverse

gear selector fork (see => page

34-67 )

Clutch lever

From 15 03 5 to 16 03 7

Lever with shoulder -1-, secured with one circlip -2-.

From Assy. date 17 03 7:

Lever with no shoulder, secured with two circlips.

Modified release shaft.

Note:

Up to 16 03 7

When installing the new shaft,

the new lever and an additional

circlip must be installed.

Checking oil level

Remove checking plug -arrow

1- with 5 mm Allen key. Oil

must be up to lower edge of

hole.

Putting oil in

Removing plug -arrow 2-.

Put in gear oil - SAE 80 or

80/90 to MIL-L 2105 (GL 4)

specifications - until oil flows

out of level checking hole.

Caution

Oil must be put in slowly to give

it time to level out uniformly in

the box. Stop for a brief period

(30 seconds) if necessary.

Modification

From Assembly date 07 05 4

Level checking hole discontinued. Oil is put in and

checked through the filler hole.

Service installation of the 5 speed manual gearbox

The 5 speed manual gearbox can be service installed in Golf and Scirocco vehicles from

August 1979 with 63 kw (85 bhp) amd 81 kw (110 bhp) engines.

The 5 speed gearbox can also be installed in vehicles built before August 1979 but this

changes the exhaust emission values slightly and may effect the vehicle Type Approval.

The following new parts have to be installed:

Designation Part No.

Gearbox 020 300 044 F

Knob 171 711 141 E

Cover plate 171 711 261 C

Relay lever 171 711 163 B

Selector rod 171 711 574 B

Selector rod 171 711 593 E

Selector lever 171 711 177 C

Mounting 171 399 113 H

Boot 171 711 195 C

Cover 171 711 210

Protective plate 171 711 229 A

and attaching parts for gearbox mountings.

Instructions on adjusting the shift mechanism are given in the booklet 5 speed manual

gearbox 020.

Note:

On vehicles up to December 1978 it may be necessary to make a small depression in the left

wheel housing in order to ensure sufficient clearance between gearbox and wheel housing. In

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.

Selector shaft cover modified

From gearbox date 22 01 0 the selector shaft cover -A- has

been provided with a rib -arrow

1- .

For this reason, the gearbox

housing has been provided with

a contact surface -arrow 2- in

the rib area.

Note:

The modified cover can only be

screwed into gearbox housings

with a contact surface.

The cover is not offered as a

service part beacuse the old

cover can be screwed into all

gearbox housings.

On some gearboxes there is an

O-ring fitted in addition under

the new cover.

On these gearboxes an O-ring

must once again be installed

when repairs are carried out.

Part No. N 903.543.01

Selector shaft lever serf-locking nut

In cases where customer complaints are received on difficult gear selection due to excessve

free play on the gearlever, it is possible that the selector shaft lever nut could be loose (see

illustration below).

Should this be loose, it must be replaced with a self-locking nut, part number N902 920 01,

avaiable from our P&A Department.