Disassembly and assembly of the gearbox control drive (VW Passat B4)

If it is necessary to replace the transmission control drive parts, remove the selector lever.

When replacing the cable and other drive parts, there is no need to remove the selector lever bracket.

Removal the selector lever and gearbox control cable

Place the vehicle on a lift. Remove the protective tray. Loosen the front selector lever mounting bolts (Fig. 4-63). Disconnect the exhaust system before the exhaust gas neutralizer. Remove the front cover. Loosen the rear selector lever mounting bolts and remove the lever. To remove the selector lever cable, perform the above operations, then:

• remove the lock washer;
• disconnect the cable eye from the selector lever (Fig. 4-64);
• disconnect the cable from the shift lever and the gearshift rod on the gearbox bracket.

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Installing the transmission control cable

Warning: The cable must not have any deflections or twists. Before installation, lubricate the eye and ends of the cable with a thin layer of grease.

Attach the cable sheath to the support and the selector lever bracket and tighten the mounting bolt to a torque of 2 kgf·m. Check the reliability of the cable sheath fastening between the bracket and the gearbox control lever and rod and lock the cable with a corrugated gasket. Attach the cable eye to the selector lever and secure it with a lock washer (Fig. 4-64).

Adjusting the transmission control cable

Set the selector lever to position "P". Loosen the flange bolt securing the cable to the gearbox control lever and rod. Set the gearbox control lever and rod to position "P". In this case, the locking lever engages the parking lock gear and locks both front wheels. In this position, tighten the flange bolt to a torque of 2.5 kgf·m.