Gear selector mechanism up to 05.99, adjusting

WARNING: This page is about a different variant/trim than selected.

Special tools and equipment

3422 Gear lever gauge

Fig 1: 3422 Gear Lever Gauge

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3192/1 Wedge

Fig 2: 3192/1 Wedge

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NOTE: The following points are essential to ensure correct selector adjustment:

Moving parts of selector mechanism and transmission elements must be in proper condition.
Selector mechanism must move freely.

The transmission, clutch and clutch mechanism must also be in proper condition.

Transmission in neutral position

Fig 3: Locating Center Console Pry Areas

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Carefully pry cover off center console (arrows).
Pull cover to rear off center console.

Fig 4: Identifying Shift Lever Knob Clip

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Destroy clip (arrow) and pull gear shift knob off with cover.
Remove rubber cover, if fitted.

Fig 5: Identifying Air Cleaner Housing & Components

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Remove intake hose -1- , connector -2- and hose -3- from mass air flow sensor.
Remove complete air cleaner housing by unscrewing bolts -4- and -5-.

Refer to 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWD, 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): AWW, AWP, 24 MULTIPORT FUEL INJECTION (MFI) for 2.0 LITER 4-CYL. 2V ENGINE MECHANICAL, FUEL INJECTION & IGNITION, ENGINE CODE(S): AEG, AVH, AZG, BBW, BEV, 24 MULTIPORT FUEL INJECTION (MFI) for 2.8 LITER VR6 2V FUEL INJECTION IGNITION, 24 MULTIPORT FUEL INJECTION (MFI) for 2.8 LITER VR6 4V FUEL INJECTION IGNITION and 24 - MULTIPORT FUEL INJECTION (MFI) for 3.2 LITER VR6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BJS

Remove balance weight. Refer to item 21 in Selector cables, removing and installing .

Fig 6: Gear Selector Cable And Actuating Arm/Gate Selector Cable Bolt & Nut

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Loosen bolt -A- and nut -B-, until gear selector cable and actuating arm/gate selector cable are free to move in elongated holes.

Fig 7: Identifying Foam Seal Bolt

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Loosen bolt -C-, pull off foam seal in area of bolt -C- if necessary.

Insert gear lever jig.
Swing jig securing hook under mounting plate and tighten nut -D-.
Press gear lever into left-hand detent of sliding piece.
Press gear lever together with sliding piece to left onto stop (direction of arrow) and tighten sliding piece with bolt -E-.

Fig 8: Pressing Gear Lever Into Right-Hand Detent

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Press gear lever into right-hand detent (direction of arrow).
Tighten bolt -C-.
Insert wedge and pin.

Fig 9: Identifying Wedge Between Gear Selector Lever And Selector Cover Plate

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Slide wedge between gear selector lever and selector cover plate, ensuring no play.

NOTE: Wedge must not lift gear lever.

In this position secure gear selector cable and actuating arm/gate selector cable. When doing this, check position of wedge.
Remove gear lever jig.
Fit balance weight. Refer to item 21 in Selector cables, removing and installing .
Fit gear shift knob and boot.

Functional check

The gear shift lever must rest in the 3rd/4th gear gate with transmission in neutral.

Operate clutch.
Select all gears several times. Pay particular attention to operation of reverse gear lock.

Should a gear fail to engage smoothly after repeated selection, the selector shaft play (lift) should be checked as follows:

Engage 1st gear.
Press gear lever to left onto stop and release. At same time observe selector shaft in gear box (2nd mechanic).

Fig 10: Selector Shaft Movement

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When moving gear lever, selector shaft must move approx. 1 mm (in direction of arrow).

Fig 11: Actuating Arm/Gate Selector Cable Mounting Nut

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If not, disengage first gear and again loosen nut -A- for actuating arm/gate selector cable mounting. (gate selector cable has a certain amount of play at mounting due to transfer elements).
Take up gate selector cable play by lightly pressing mounting toward bulkhead (direction of arrow).
Tighten nut -A- in this position.