Saturday, October 04, 2003

Google Search: golf shifter cassette trick: "Q: How can I improve shift effort/meshing of my gears? First gear feels like
there is something blocking it?
A: First check out the linkage adjustments, regrease where needed, and older
cars, possibly replace the old linkages/bushings. A special spacer tool is
needed for one of the adjustments (A1 & A2) which happens to be exactly the
same size as the skinny side of an audio cassette. Other special tools may
be needed.

The end of the shift lever has a ball on it that fits into a cup.
The cup wears and allows the ball to ride lower and lower. Pretty soon,
the ball, with shifter attatched, is riding so low that you don't need
to push down to bypass the reverse lock out.
All you need to do is replace the ball and cup. While you're in there,
replace theshifter bushings for the feedthrough.
See the Bentley manual for an excellent description.
BTW, you'll most likely have to drop the exhaust to get at the parts.
I have done this operation several times on various models, and can
honestly say that it can be done in about 2 hours or less if you
have a torch to remove the old exhaust clamps.

Also check out whether the motor/transmission mounts are ok, misalignment
will cause shifting problems as will a dragging clutch.
If your shifting effort is hard/stiff on cold days & grinds in 1st & 2nd,
but easier once warmed up you may want to change to a synthetic
transmission fluid (see performance FAQ).

Also see the G60_Xmission_Mods, faq.vw.perf, Solid_Shifter for adding a
counter weigh"

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