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VW
Shifter
Last Monday morning,
a customer drove his 1995 Volkswagen Jetta® into the service
drive. As he got out of the car, I noticed his clothes were all wrinkled,
his tie was loose and yanked over to one side and he had a crazed look in
his eyes.
" I can't take
it anymore", he said. "That constant buzzing and knocking from
the gear shifter is driving me crazy!"
Seeing that he was
really on the edge I said, "Why don't you have a seat over here with
a cup of coffee so we can talk about it."
"So, how long
has the shifter been doing this and in which gears," I asked. Gazing
down at the floor, he relayed that it started about six months ago, and
since then the problem has been getting progressively worse.
"At first the
radio could drown out the noise, but now I can't turn it up loud enough,"
he mumbled. "It happens mostly in third and fourth gears and knocks
when I let off the accelerator." We talked about the problem a little
more, then wrote up the repair order.
After he signed the
repair order and left, I scanned the factory service bulletins for his
vehicle on my ALLDATA information system. I found exactly what he described.
The service bulletin explained that the problem could effect any Volkswagen
Passat®, Golf® or Jetta®
with the 02A transmission, as well as Passats® with the
02C Synchro-transmissions sold in Canada.
Normal transmission
vibrations traveling through the selector shaft and shifter cables may
cause the shift lever to vibrate and knock in 1st, 2nd, 3rd or 4th gears.
When this condition exists, the following repair is recommended.
Note: The transmission
must remain in neutral throughout the procedure.
Disassembly
1. Remove electrical connector from back-up light switch housing.
 2.
Remove nut (B) and balance weight (A) from gear selector
cable attachment.
3. Remove gear selector
cable from gear selector lever.
4. Disconnect gate
selector cable from actuating arm/relay lever (C) by lifting lug
in direction of (arrow).
5. Remove 2
bolts securing back up light switch housing (D) and remove housing.
6. Remove self-locking
nut (7) and back-up light switch cam sleeve (6).
 7.
Remove gearshift lever (12).
8. Remove selector
shaft housing attachment bolts (arrows). Note: tap housing lightly
with brass or plastic mallet to loosen.
9. Remove selector
shaft with housing from transmission.
Modification
1. Enlarge both selector shaft housing attachment holes to 9 mm (approx.
23/64 in.).
2. Reinstall selector shaft with housing using sealant AMV 188 200 03
or equivalent, then adjust according to one of the following conditions:
 Vibration
or knocking from 1st or 3rd gear: Turn housing right (clockwise as far
as possible). Vibration
or knocking from 2nd or 4th gear: Turn housing left (counter clockwise
as far as possible). Torque bolts to 25 Nm. (18-ft. lb.).
Installation
 1.
Reinstall gearshift lever.
2. Reinstall back-up
light switch cam sleeve (always use a new self-locking nut). Torque nut
to 25 Nm. (18-ft. lb.).
3. Reinstall gate
selector cable to actuating arm/relay lever by lifting lug (C)
in direction of (arrow).
4. Reconnect gear
selector cable to gear selector lever (position cable pivot in center
of slot on selector lever).
5. Reinstall balance
weight (A).
6. Reinstall back-up
light switch housing (D).
7. Reinstall back-up
light switch electrical connector.
8. Road test the vehicle,
making sure the vibration and knocking is gone.
After road testing the vehicle and confirming that the repair was complete,
I got to do the best part of my job. No, not collecting the money. I got
to tell my customer that his Jetta® was repaired and see
the huge smile on his face. He couldn't thank me enough. The cost of this
repair, he felt, was money well spent.
©
2000 ALLDATA LLC
Written
by ALLDATA Technical Editor, Rich Diegle.
Rich is an Advanced Engine Performance Certified and ASE Master Technician with
an Associate of Arts degree in automotive technology and 22 years of dealership
and independent shop experience.
ALLDATAź
is a registered trademark of ALLDATA LLC
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