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
rod

Adjusting bearing

(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
rod

Adjusting selector

(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 -2back and retaining screw

-1- in.
Press selector shaft -4in 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 -2and 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.
2.
3.
4.

Boot with cap

One-piece shift rod bearing
Relay lever with larger rubber ball
Type of grease

from April 1981

from August 1980
from February 1982

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.

12bearing
3456-

Relay lever
Shift rod
Shift rod
Clamp
Selector rod
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)
Gearbox to engine
(M 10)
Drive shaft to flange
Left mounting to
gearbox
Shift rod to linkage

- 75
Nm
- 45
Nm
- 45
Nm
- 40
Nm
- 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 highmounted 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

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)

Clutch push rod

o Grease at
bush in
drive
shaft
(multipur
pose
grease)

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.

Removing and installing Housing

Removing

Installing gearbox in
repair stand - VW.

Pull

Installing gearbox in
repair stand - Audi.
clutch rod out
downwards.

Fitting support bar

for drive shaft - VW

A - Locknut M 12.

Lift

A - Locknut M 12.

VW 295a into
contact with drive shaft
with screw and lock.

Fitting support bar

for drive shaft - Audi.

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 -3and 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
Gearbox
Knob
Cover plate
Relay lever
Selector rod
Selector rod
Selector lever
Mounting
Boot
Cover
Protective plate

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

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.