I have just swapped the engine and gearbox on a 1.0 2001 Polo. They came out of a Lupo but they were the same. Engine was an AUC and the gearbox was an ESY.

Anyway the engine got the works, Dayco cambelt kit, water pump with metal blades, new Sachs clutch kit, plugs and leads and even fully synthetic oil, my rewards is she purrs like a kitten.

The gearbox got fresh oil but my reward there is she will not select reverse and try as I might I can't figure out why. If I ram it left it will get reverse sometimes but not always. Left and right on the gear stick translates into rotation of the selector shaft on the box, the problem I have is that the cable for that goes over a pin on the selector and is locked in with a clip. There appears to be no adjustment to give me that little bit of extra rotation. What am I missing?

I have seen other posts that speak of a jig but it shouldn't be that hard.

Thanks all.

Edited 11 December, 201411 yr by markandcath

OK it is sorted and it was a bit of a faff but here goes to help people out.

There are in fact 2 adjustments and you don't need a jig, just a bit of patience and a helping hand is always good.

In the picture below you see the 2 adjustment points A & B

Simply centre point A in the groove, you can move it later but all it sets is the neutral line (left and right on the gear stick) You can move it further away so you are reaching for the gear stick or closer to you. We all know where feels right so loosen the nut, set the reach and tighten the nut. Job done. Mine was centre but yours may be different.

Point B is a tricky one. As you move the gear stick left and right the mechanism translates this into rotation on the selector shaft on the gearbox (get someone to do it while you watch). Reverse is the key so loosen the nut, move the bolt 1mm and try to get reverse. Repeat until you can get it every time. Note this as Point 1.

Now don't stop there keep going 1mm at a time until 5th is hard to get, Note this as point 2.

Now set the adjuster half way between point 1 & 2 and it will be perfect every time after that.

Edited 12 December, 201411 yr by markandcath

Very good advice there.

Iirc all the jig does is lock the selector in reverse and then you get under it and force adjuster b into reverse and manipulate the mechanism to fully select reverse. Could be wrong.

There is also an adjuster inside the car to the front of the gearstick. Undoing it realises the tension on the spring and from what I gathered allows you to set the neutral position left and right.

Also worth mention that if you haven't done any major work ie remove the gearbox or engine and your gears suddenly don't select, there is a high possibility that the lower mount has worn out. This is most commonly due to oil contamination. Get under the car and use a long pole etc to lever the gearbox against say the subframe and move it forwards. This should be difficult to do if the mount is good, and very easy if it's worn. You will also feel it fight you when you decelerate as it shakes a good bit as if the clutch springs have worn.

Edited 13 December, 201411 yr by dixy