TRANSMISSION SERVICING - M/T

Article Text
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Tuesday, August 24, 1999 12:06AM

ARTICLE BEGINNING

1989-90 TRANSMISSION SERVICING

Manual Transmission Servicing

Cabriolet, Fox, Golf, GTI, Jetta, Jetta GLI, Vanagon

IDENTIFICATION

VOLKSWAGEN MANUAL TRANSMISSION APPLICATIONS

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Model Transmission

Cabriolet ................... 5-Speed - 020 Transaxle

Fox ......................... 4-Speed - 014 Transaxle
Golf ........................ 5-Speed - 020 Transaxle
GTI ......................... 5-Speed - 020 Transaxle
Jetta & Jetta GLI ........... 5-Speed - 020 Transaxle
Vanagon ................... 4-Speed - 091 Transaxle
5-Speed - 094 Transaxle
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LUBRICATION

SERVICE INTERVALS

No oil changes are required. Check oil every 15,000 miles.

CHECKING FLUID LEVEL

CABRIOLET, GOLF, GTI, JETTA & JETTA GLI

1) Because of transaxle mounting angle, oil will run out of

checking hole even though transaxle is filled to capacity. To check
oil level, place vehicle on level surface.
2) Remove oil filler plug. Allow oil to drain off until level
is to edge of hole. See Fig. 1. Install oil filler plug. Remove
speedometer cable at transaxle. Pour in .5 qt. (.5L) of fluid.

FOX & VANAGON

Check lubricant level at fill hole. Lubricant should be level

with bottom of fill hole.
 TRANSMISSION SERVICING - M/T
Article Text (p. 2)
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Tuesday, August 24, 1999 12:06AM

Fig. 1: Fluid Level Check (Cabriolet, Golf, GTI & Jetta)

Courtesy of Volkswagen United States, Inc.

RECOMMENDED FLUID

Use API GL-4, SAE 80W or 80W-90.

FLUID CAPACITY ADJUSTMENT

TRANSMISSION REFILL CAPACITIES

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Transmission Qts. (L)

020 ............................. 2.1 (2.0)

014 ............................. 1.8 (1.7)
091 ............................. 3.2 (3.0)
094 ............................. 4.7 (4.5)
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GEARSHIFT LINKAGE ADJUSTMENT (CABRIOLET)

1) Pull boot off housing. Loosen shift rod clamp bolt so

lever moves freely on shift rod. Adjust shift finger in center of
lock-out plate so that an equal distance is obtained on both sides of
 TRANSMISSION SERVICING - M/T
Article Text (p. 3)
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Tuesday, August 24, 1999 12:06AM

shift finger. See Fig. 2.

Fig. 2: Adjusting Cabriolet Shift Finger

Courtesy of Volkswagen United States, Inc.

2) Adjust shift rod end so distance "A" is 9/16". See Fig. 3.

Tighten shift rod clamp to 14 ft. lbs (19 N.m). If shift linkage is
spongy or jamming after adjustment, change distance "A" to 1/2". If
shift linkage will not stay adjusted, install a new clamp bolt and
lock nut.

Fig. 3: Adjusting Cabriolet Shift Rod End

Courtesy of Volkswagen United States, Inc.
 TRANSMISSION SERVICING - M/T
Article Text (p. 4)
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Tuesday, August 24, 1999 12:06AM

GEARSHIFT LINKAGE ADJUSTMENT (FOX)

1) Shift transaxle into 1st gear. Push gearshift lever to

left stop. Release lever. If lever does not spring back 1/4-3/8" (5-10
mm) to right, move gearshift lever very slightly in elongated holes.
If adjustment does not correct hard shifting, go to step 2).
2) Place gearshift lever in the "Neutral" position. Place
lever bearing housing in center of elongated hole. Loosen shift rod
clamp nut. See Fig. 4. Ensure that shift finger slides freely on shift
rod. Remove gearshift lever knob and shift boot.
3) Align centering holes of gearshift lever housing and
gearshift lever bearing housing. Tighten bolts. Install Gearshift
Aligner (3014) with locating pin toward front of vehicle. See Fig. 5.
4) Move gearshift lever into left cutout of slide. Secure
tool position by tightening lower knurled knob on tool. Move slide
with gearshift lever to the left side stop and tighten upper knurled
knob.
5) Push gearshift lever into right cutout of slide (shift
position for 3rd/4th gears). Align shift rod and shift finger (with
transmission in Neutral) and tighten clamp nut. Remove tool and move
gearshift lever into 1st gear. Press gearshift lever to left side
stop. When gearshift lever is released, it must spring back
approximately 1/4-3/8" (5-10 mm).

Fig. 4: Shift Rod Clamp Nut

Courtesy of Volkswagen United States, Inc.
 TRANSMISSION SERVICING - M/T
Article Text (p. 5)
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Tuesday, August 24, 1999 12:06AM

Fig. 5: Gearshift Aligner (3014) Installed On Fox

Courtesy of Volkswagen United States, Inc.

GEARSHIFT LINKAGE ADJUSTMENT (GOLF, GTI, JETTA)

GOLF, GTI, JETTA & JETTA GLI

1) Place shift lever in the "Neutral" position. Ensure that

transaxle is also in the "Neutral" position. Loosen lower shifter rod
clamp. See Fig. 6. Selector lever must move freely on shifter rod.

Fig. 6: Shift Rod Clamp (Golf, GTI, Jetta & Jetta GLI)
Courtesy of Volkswagen United States, Inc.

2) Remove gearshift knob and boot. Position Adjustment Gauge

(3104) over shift rod. See Fig. 7. With transaxle in Neutral, align
shift rod with selector lever. Tighten shifter rod clamp to 19 ft.
 TRANSMISSION SERVICING - M/T
Article Text (p. 6)
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Tuesday, August 24, 1999 12:06AM

lbs. (26 N.m).

3) Move gearshift lever through entire range of gear
selection, including Reverse. Gears must engage smoothly and without
jamming. Reinstall gearshift knob and boot.

Fig. 7: Adjustment Gauge Location

Courtesy of Volkswagen United States, Inc.

GEARSHIFT LINKAGE ADJUSTMENT (VANAGON 4-SPEED)

1) Place gearshift lever in the "Neutral" position. Align

round centering holes of upper gearshift lever housing plate with
holes in lower lever bearing plate.
2) Loosen nut on clamp that connects front and rear shift
rods. Ensure joints of shift rods slide freely. Remove spare tire. Set
shift lever on transaxle in vertical "Neutral" position.
3) At gearshift lever end of front shift rod, ensure stop
finger of front shift rod is in center of shift mechanism housing.
4) Adjust front shift rod end so there is 29/32" (23 mm)
clearance between front shift rod end and stop plate. Tighten shift
rod clamp.
5) Check for proper operation. Ensure shift lever does not
rub against heater pipe insulation.

GEARSHIFT LINKAGE ADJUSTMENT (VANAGON 5-SPEED 2WD)

1) Place gearshift lever in the "Neutral" position. Align

round centering holes of upper gearshift lever housing plate with
holes in lower lever bearing plate.
2) Loosen nut on clamp that connects front and rear shift
rods. Ensure joints of shift rods slide freely. Remove spare tire. Set
shift lever on transaxle in vertical "Neutral" position.
3) Push shift rod into transmission until spring tension is
felt. Keep shift rod in this position (2/3 shift position). Push shift
rod to right (shift position for 1st/reverse) and move in lengthwise
direction.
4) Measure between reverse gear lock and stop shift rod.
Clearance should be 1/8" (3 mm). Let shift rod spring back to 2/3
shift position. Push shift rod slightly to the right. Boot must touch
 TRANSMISSION SERVICING - M/T
Article Text (p. 7)
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright © 1998 Mitchell Repair Information Company, LLC
Tuesday, August 24, 1999 12:06AM

inside of shift housing.

5) Tighten shift rod bolt. With transmission engaged in 2nd
gear, measure distance between gear shift lever and heater covering.
Clearance should be 5/8" (16 mm).
6) If clearance is not to specification, adjust gearshift
lever bearing by pushing backward in slotted holes. Ensure all gears
engage without jamming.

GEARSHIFT LINKAGE ADJUSTMENT (VANAGON 5-SPEED SYNCRO)

1) Place gearshift lever in the "Neutral" position. Align

round centering holes of upper gearshift lever housing plate with
holes in lower lever bearing plate.
2) Loosen nut on clamp that connects front and rear shift
rods. Ensure joints of shift rods slide freely. Remove skid plate. Set
shift lever on transaxle in vertical "Neutral" position.
3) Measure between reverse gear lock and stop shift rod.
Clearance should be 29/32" (23 mm). Tighten clamp in this position.
Ensure all gears engage without jamming. Check reverse lockout
operation. With transmission engaged in 1st gear, measure distance
between gear shift lever and heater covering. Clearance should be
19/32" (15 mm).

END OF ARTICLE