1997 1.4 8v

Hi everyone another thing on my list to do is the gearlinkage cable adjustment.

The gears are getting harder to select and the gearstick (when in gear) feels really slack/floppy.

I read in Haynes that they say it is a specialist job and needs a VW tool. Does anyone know where to get one, or have plans to make one?

I guess I just need to know if its a DIY job or not.

`cheers

Russ

Servicing selector mechanism (cable selector mechanism)

Adjusting gear selector mechanism (cable control gear selection)

Gearbox in neutral.

‒ Pull gear stick knob off with gaiter =>Page 34-11.

‒ Remove insulation tray below engine/gearbox, if fitted.

‒ → Loosen bolt -A- and nut -B-, until the gear change cable and relay lever ball head/gate change cable are free to move in the elongated holes.

‒ → Loosen bolt -C- .

‒ Insert gear stick jig.

‒ Swing jig securing hook under mounting plate and tighten nut -D-.

‒ Press gear stick into left-hand detent of sliding piece.

‒ Press gear stick together with sliding piece to left onto stop (direction of arrow) and tighten sliding piece with bolt -E-.

‒ → Press gear stick into the right-hand detent (direction of arrow).

‒ Tighten bolt -C-.

‒ → Tighten bolt -A- and nut -B-.

Note:

‒ Do not move selector finger and ball head when tightening.

‒ Remove gear stick jig.

Functional check

● In neutral the gear stick must be in the 3rd/4th gear gate.

‒ Operate clutch.

‒ Select all gears several times. Pay particular attention to the operation of the reverse gear lock.

Should a gear fail to engage smoothly after repeated selection, then continue as follows:

‒ Pull gear stick knob off with gaiter =>Page 34-11.

‒ → Then pull the centre console cover, vertically upwards (arrows).

‒ Engage 1st gear.

‒ Remove play from selector mechanism by carefully pushing gear stick to the left.

‒ Then press gear stick firmly to left onto stop (direction of arrow).

→ This additional movement moves the lower end of spring back distance -a-

‒ Determine distance -a- with the depth gauge of a vernier caliper.

‒ → Do this by laying vernier gauge horizontally on spring (arrow 1).

‒ Measure distance of spring (arrow 1) to bearing plate (arrow 3) to beginning and end of additional movement in each case.

‒ → Distance -a- must be 1...3 mm.

‒ If this is not the case, adjust selector mechanism =>Page 34-20.

Note:

‒ The measuring sequence is performed with the console installed (shown removed for ease of illustration) but without frame.

nice one Nige.

The adjustment looks pretty complex and the jig too hard to make.

Do you know where you an get the jigs? I'm guessing a VW garage will be very expensive to pay for labour.

nice one Nige.

The adjustment looks pretty complex and the jig too hard to make.

Do you know where you an get the jigs? I'm guessing a VW garage will be very expensive to pay for labour.

I can't see any of the tool makers (Draper, Snap-on, etc) making a copy, so unless you can befriend a VW mech to borrow the tool overnight? you will have to assume the postion while the stealership probes your rusty bullet hole!!!

hmmmmmm,

I wonder if gearbox specialists would do cable adjustment?

The gearbox and clutch seem fine themselves, the gear change just feels really worn and soggy. I was hoping i'd be able to get it tightened up to improve feel?

hmmmmmm,

I wonder if gearbox specialists would do cable adjustment?

The gearbox and clutch seem fine themselves, the gear change just feels really worn and soggy. I was hoping i'd be able to get it tightened up to improve feel?

I did find a company that sells the VW tool it's a US based company $89 + P&P www.baumtools.com via google search for vw special tool 3192 Iwould of thought that someone in Germany would of made copies but none came up! & nothing found on ebay.de

I doubt if gearbox companies would do the cable adjustment, they would send you to the main stealership, as it requires that tool, but it might be worth a telephone call?

I wonder if you got a replacement lever assy from a scrappy from a newer car it might not be so sloppy??

thats an idea but wouldn't I still need to disconnect the cables at the gear stick end?

I read in my Haynes there is an adjustable (DIY) rod linkage fitted to other polo gearboxes. Just out of interest can you mix and match the different engine codes and gearboxes? if they are the similar ie. both 1.4 8v ? (say from an earlier or later year?) In other words would my engine be able to fit a rod type gear box Nige?

ouch they want 250 dollars plus postage

:(