02J 5-Speed Manual FWD

Gear selector mechanism, adjusting
Special tools and workshop equipment required





^ T10027 Retaining pin

Notes: The following points are essential to ensure correct selector adjustment:
^ Parts of selector and relay 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.





Disengage retainers for gear selector cable and gate selector cable as follows:
- Push back collar -1- as far as it will go in direction of arrow - 2 -.
- Turn collar -1- as far as it will go in direction of arrow -3- and allow it to engage.





Notes:
^ The selector cable -4- must be free to move within the retainer.
^ The illustration shows the gate selector cable. The retainer on the gear selector cable can be disengaged in the same way.

- Push selector lever -1- downward into Gate for 1st/2nd Gear (arrow A). At the same time, turn adjuster pin -2- so that it points upward (arrow B) and allow it to engage.
- Adjuster pin -2- must point vertically upward.





- Remove gear stuck knob - 1 -.
- Remove bolts - 2 -.
- Lift off retainer ring -3- and gaiter- 4 -.





- Use retaining pin T 10027 to lock the gear stick in position.





- Make sure that gate selector cable -1- and gear selector cable -2- are properly inserted in their retainers -3- and are not under tension.
- Turn each collar - 4 as far as it will go in direction of arrow, then release.





- Turn back adjuster pin - A - in direction of arrow.
- Adjuster pin - A - must be horizontal
- Pull retaining pin T 10027 out of selector mechanism.
- Fit gear stick knob and cover (gaiter).

Checking operation
- The gear stick must rest in the 3rd/4th gear gate when the transmission is in neutral
- Operate clutch.
- Select all gears several times. Pay particular attention to the operation of the reverse gear lock.
- It should only be possible to engage reverse gear after pressing the gear stick down to overcome the reverse gear lock.
- Should a gear fail to engage smoothly after repeated selection, check the selector shaft play (lift) as follows:
- Engage 1st gear.
- Press gear stick to left onto stop and release.





- At the same time observe selector shaft in transmission (2nd mechanic).
- When moving the gear stick, the selector shaft must move approximately 1 mm (in direction of arrow).
- If the gear stick is not correctly adjusted, repeat the adjustment procedure.