Adjusting Intermediate Lever (Transmission Connection): Tools

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Fig 1: Identifying Special Tools - Adjusting Intermediate Lever

Courtesy of PORSCHE OF NORTH AMERICA, INC.

SPECIAL TOOLS - ADJUSTING INTERMEDIATE LEVER

Item

Designation

Special tool

Explanation

A⁽¹⁾

Removal tool

commercially available

B⁽¹⁾

Threaded piece

VW 771/15

C⁽¹⁾

Hexagon-head bolt M10 x 110

commercially available; make a 5 mm wide and 3 mm deep groove in the head.

⁽¹⁾	For explanation see Fig 1 .

Fig 2: Identifying Intermediate Lever Components

Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: The intermediate lever is machine-caulked as standard after adjustment of the shift mechanism. If the transmission connection or parts of the transmission connection are replaced during repairs, the caulked intermediate lever must be exchanged for an adjustable intermediate lever and readjusted.

A misadjustment of the intermediate lever can result in the following problems:

higher shifting friction.
1st, 2nd, 5th or reverse gear cannot be engaged.

Move shift lever to neutral position and disengage shift cables on the transmission. Use a commercially available removal tool for this purpose.
Disengage end piece of intermediate lever at shift lever "B". See Fig 3 .

Fig 3: Disengaging End Piece Of Intermediate Lever
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Turn relay shaft "A" counterclockwise to push it to the upper stop and fix it with suitable weight (e.g. special tool 9390). See Fig 4 .

Fig 4: Turning Relay Shaft Counterclockwise
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Turn shift lever "C" counterclockwise to the upper stop (shift gate 1/2) and fix with shop-made tool. See Fig 5 .

Fig 5: Turning Shift Lever Counterclockwise To The Upper Stop
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Adjust the length of the intermediate lever by means of the thread until the end piece can be pressed onto the upper ball pin without tension.
NOTE: The face sides of the intermediate lever end pieces must be at right angles to the center axis of the ball pins.

Fig 6: Intermediate Lever End Pieces At Right Angles To The Center Axis Of The Ball Pins
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Tighten lock nut.
Press shift cables onto the ball pins and check shifting function.

NOTE:

Ball socket and ball pin versions with retaining clips must be lubricated with a light coat of universal low-temperature grease.
Do not grease ball socket and ball pin version without retaining clips (as of date of manufacture 22.4.97).