So I got sick of my sloppy whore shifter and bought a sloppy shifter rebuild kit from http://www.dieselgeek.com for 33.00shipped! I did it in my shop and it took a total of 2 hrs. At home it would take longer, especially if you dont have 3/8 impact gun to take the rusted nuts off.
You can replace the 2 white plastic bushings and the white selector square bushing and be done in less than an hour. Replacing the orange shaft bushing requires alot more work (but I wanted to do it all because I had it 1/2 off anyway.)
kit consists of all the stuff needed! plus orange bushinf i forgot to put in the picture.
Start by taking a look at the linkage. I have a turbo kit on mine so the DP and o2 sensor kinda get in the way but its not too bad. Apply lots of deep creep or rust penetrant to the 13mm bolt and then release the tab on the black ball at lower circle. The 2 arrows point to 2 of the pieces being replaced. I had to use a 13mm swivel with 3/8 impact to break loose the nut cuz it was rusted, I tried w/ a ratchet but no success.
Make sure to hold on to the counter weight when loosening the nut or the linkage may break and it does move.
After removing the linkage from the top of the shaft move it aside. Also move the rod aside. (Be careful removing the rod from the ball, it may break and they do break easily, but if it does break there only about 6.00 at the dealer if they stock it)
This picture shows the 2 white plastic busings you replace. If you are doing the orange busing now is the time to remove the 13mm nut on the shift shaft. ( Lube it up 1st with the rust penetrant to help loosen it up.) I had to use my impact yet again because it was soooo rusted on.
Remove the top bushing with a screwdriver or whatever works and push the shaft down. Circles represent the 3 13mm bolts that hold the bracket down, take the selector shaft our 1st before removing the bolts and taking the bracket off, its easier that way.
From under the car remove the clip that holds the shifter shaft in. Then press the shaft back up all the way and out and then out of the bracket. yay! As you can see on mine, using the impact actually bent the selector arm where the white bushing goes, i just hammered it back when it was in a vice and all good. Remove the clamp that holds the bracket for the ball/ square shifter bushing and slide the bracket off the shaft. Now take out the 3 13mm bolts and jimmy the bracket out.
Once out you will notice the orange bushing is in there good. Its actually sandwiched between the bracket and a small bracket via 2 rivets. Drill them out!
When re-installing lube up the bushing lots!!! more the better, on the outside before you re-rivet the brackets together and the inside for when you re-insert the bracket on the shift shaft.
As you can see the ball was totally junk, cracked and falling apart. The white bushings were pretty worn also and the orange bushing was junk and soft.
Now, put the white bushing on the bottom of the bracket and inser the shaft up in the top hole than in the bottom and push all the way down. Dont forget the lube. Then insert the top bushing and lube it up and press the shaft all the way up. (NOTE!! dont put both bushings in then try to put the shaft in, it wont go, trust me i tried and then had to take the top bushing out and redo it.) Put the clip on and then re-insert the bracket back to the shaft. I used 3 new bolts because the old ones were rusty and looked weak. There 8X30mm bolts I believe.
Put everything back on and lube up the white square bushing on the middle and sides andslide everything back on. I had troubles getting the shift shaft to insert into the bracket and needed a 2nd hand to wiggle/push on the shift lever while I was wiggling/pushing on the bracket. Once in re-install the black rod and clip closed. Install the other bracket on top of the selector rod and use a new nut and washer and tighten down. ( remember to hold the counterweight)
Now to adjusting the linkage. I reccomend doing it if just replacing the white square bushing and 2 plastic bushings (you can get those out w/o removing the bracket) But if you remove the bracket and touch the 13mm nut on the end of the shift shaft you MUST ADJSUT THE LINKAGE!!!!!!!!!! <--------- unless you like grinding gears or attempting to adjust manually. The special tool is vw 3104 I bought mine offa ebay for like 12.00 shipped. Dealer most likely wont have one either and the vw one is made of plastic...... cheap.....
Before tightening the clamp with the bolt in it put the tool on the shifter like so. it only goes on one way so you cant mess up.
Once thats on and the linkage is set put the bolt through the bracket and tighten a NEW NUT BOUGHT AT HARDWARE STORE LIKE OTHER NEW STUFF on the end and tighten down good.
My shifter was still a little out of specs so I decided to adjust this also. It moves in an eccentric when you turn it and the spec is like 1-1.5mm between the side and the little arm on the shifter. I just eyeballed it. Its a 4mm allen, I loosened it up 3 turns and then spun the shaft 180deg and its good. The arrow points the the gap thats the specs. MAKE SURE TO DO THIS IN 1ST GEAR!
Before driving go through all the gears 10-20times to loosen everything up. It should be tight but not REAL tight. If its hard to get into any gear just loosen that nut on the shift shaft and put the bracket back on and re-tighten it. If there is any play left while in gear the actual shift lever bushing is bad, but a new short shift kit will fix that. I think its fine as is even though there is a little play.