See Figure 1
Check the cable adjustments on all models as follows:
- Run the engine at 1,000-1,200 rpm with the parking brake on and the wheels blocked.
- Select the Reverse gear. A drop in engine speed should be noticed.
- Select the Park position; engine speed should increase. Pull the shift lever against the stop in the direction of Reverse. The engine speed should not drop (because reverse gear has not been engaged).
- Move the shift lever to engage the Reverse. Engine speed should drop as the gear engages.
- Move the shift lever into Neutral. An increase in engine speed should be noticed.
- Shift into Drive. A noticeable drop in engine speed should result.
- Shift into 1. The lever must engage without having to overcome any resistance.
- To adjust the cable, shift into Park, then proceed as follows:
- On Dashers before chassis no. 3-5 2 044 957, remove the cover from the bottom of the shift lever case under the car and loosen the cable clamp. Using pliers, press the lever on the transaxle to the rear (against spring tension) until it hits the stop, then tighten the clamp.
- On Dashers with chassis no. 3-5 2 044 957 and later, as well as Quantums, the shift cable clamp is loosened from inside the passenger compartment. Have an assistant under the car press the transaxle lever toward the Park position and tighten the clamp.
- On all models except Dasher and Quantum, loosen the cable clamp at the transaxle end of the cable. Press the transaxle lever all the way to the left, then tighten the cable clamp.
Except 1985-89 Golf and Jetta
See Figure 2
Early Dashers with the type 003 automatic transaxle (identified by the modulator hose attached to the driver's side front of the transaxle above the pan) have a kickdown switch rather than a throttle cable. See the appropriate procedure for the switch test.
- Make sure the throttle is closed. On carbureted models, the choke and fast idle cam must be off.
- Detach the cable end at the transaxle.
- Press the lever at the transaxle into its closed throttle position.
- You should be able to attach the cable end onto the transaxle lever without moving the lever.
- Adjust the cable length to the correct setting.
- Warm up the engine and move the gearshift lever to Park.
- Loosen the adjusting nuts and remove the accelerator cable.
- Remove the nuts on the throttle cable support bracket.
- Grasp the throttle cable by the sleeve and push it way from the lever until all play is removed from the cable. While doing this, make sure the throttle valve and the accelerator/transaxle linkage remain in the closed position.
- When all slack is removed from the cable, hold it and tighten the adjusting nut until it contacts the support bracket. Tighten the locknut to 7 ft. lbs. (10 Nm).
- Install and connect the accelerator cable.
At this point an assistant will be needed to complete the adjustment procedure.
- Have an assistant press the gas all the way down until it hits the stop.
- Move the transaxle operating lever against the kickdown stop and remove all the slack from the cable by turning the adjusting nut.
- Let up on the gas pedal and push it all the way down again. Make sure the operating lever rests against the kickdown stop and tighten the locknut.
KICKDOWN SWITCH CHECK
Early Dashers with the type 003 automatic transaxle (identified by the modulator hose attached to the driver's side front of the transaxle above the pan) are the only VWs equipped with kickdown switches. All other models have throttle cable kickdowns.
- Turn the ignition switch ON .
- Floor the accelerator. You should hear a click from the solenoid on the transaxle.
- Replace the solenoid if no sound is heard. The solenoid is housed in the valve body and is accessible only by removing this unit from the transaxle; this job is best performed by a qualified mechanic.
FRONT AND REAR BANDS
See Figure 3
These adjustments apply to Dashers with the 003 transaxle only. The type 003 transaxle is identified by the modulator hose attached to the driver's side front of the transaxle above the pan.
The adjustment screws are located at the top of the transaxle housing, with the 1st gear (front) band being closest to the front of the unit on the passenger's side of the car. The 2nd gear (rear) band adjustment screw is located toward the rear of the unit on the driver's side of the vehicle.
The transaxle must be horizontal when the band adjustments are performed.
- To adjust the 1st gear band, loosen the locknut and tighten the adjusting screw to 84 inch lbs. (10 Nm).
- Loosen the screw and retighten it to 42 inch lbs. (5 Nm).
- Turn the screw out 3 1 / 4 -3 1 / 2 turns, then tighten the locknut.
- To adjust the 2nd gear band, repeat Steps 1-2, then turn the screw out exactly 2 1 / 2 turns before tightening the locknut.