REMOVAL & INSTALLATION
See Figure 1
- Disconnect the negative battery cable.
- Remove the engine.
- Make a bracket to hold the torque converter in place. If a bracket is not used, the converter will slide off the transmission input shaft.
- Detach the gearshift rod coupling.
- Disconnect the drive shafts at the transmission end. If the driveshafts are not going to be repaired, it is not necessary to detach the wheel end.
- Disconnect the drive ATF hoses from the transmission. Seal the open ends. Disconnect the temperature switch, neutral safety switch, and the back-up light switch.
- Pull off the vacuum servo hose.
- Disconnect the starter wiring.
- Remove the front transaxle mounting nuts.
- Loosen the rear transaxle mounting bolts. Support the transaxle and remove the bolts.
- Lower the axle and remove it from the car.
- With the torque converter bracket still in place, raise the axle into the car.
- Tighten the nuts for the front transmission mounting. Insert the rear mounting bolts, but do not tighten them at this time.
- Replace the vacuum servo hose.
- Connect the ATF hoses, using new washers. The washers are seals.
- Connect the temperature switch and starter cables.
- Install the driveshafts, using new washers. Turn the convex sides of the washers toward the screw head.
- Align the transaxle so that the inner drive shaft joints do not rub on the frame fork and then tighten the rear mounting bolts.
- Insert the shift rod coupling, tighten the screw, and secure it with wire.
- Remove the torque converter bracket, and install the engine.
- After installing the engine, bleed the ATF lines if return flow has not started after 2-3 minutes.
SHIFT LINKAGE ADJUSTMENT
See Figures 2, 3, 4 and 5
The Volkswagen shift linkage is not adjustable. When shifting becomes difficult or there is an excessive amount of play in the linkage, check the shifting mechanism for worn parts. Make sure the shift linkage coupling is tightly connected to the inner shift lever located at the rear of the transaxle under a plate below the rear seat on Types 1, 3 and 4. On Type 2 models, Check the setscrew where the front shift rod connects to the center section below the passenger compartment, and the rear setscrew where the linkage goes into the transaxle. Worn parts may be found in the shift lever mechanism and the supports for the linkage rod sometimes wear out.
The gear shift lever can be removed after the front floor mat has been lifted. After the two retaining screws have been removed from the gear shift lever ball housing, the gear shift lever, ball housing, rubber boot, and spring are removed as a unit.
Installation is the reverse of removal. Lubricate all moving parts with grease. Test the gear shift pattern. If there is difficulty in shifting, adjust the stop plate back and forth in its slotted holes.