Shift Linkage Adjustment for a 1996 Passat

[TennesseeSteve]

Here's my problem: I found the service manual procedure for an 02A transaxle shift linkage adjustment under a Shopkey pro search for a 1996 VW Passat TDI. The service manual states that special tool 3192 (shift linkage adjustment bracket) is required for this job. The only two for sale online I could find were $150 from Snapon and $250 used one on Ebay. After digging on Youtube I found no videos of anyone doing an adjustment on an 02A without the tool, although I did find some dieselgeekdotcom videos of shift linkage adjustments on MK4, MK5, and MK6 trans. In those videos, however, the shift lever had a bracket on it that accepted a 5mm pin, which locked it in place. Mine does not have that feature as far as I can see, and I suppose that is probably what the expensive bracket tool is for.
As far as I can see my options are as follows.
1) I can just leave it alone and ignore the sloppy shifting. (I'd rather not, because it's annoying and I'm afraid grinding gears in 1st and 3rd overtime will lead to a ruined transaxle or starting in 2nd will wear out the clutch)
2) Hopefully there is something I've overlooked and I can adjust the shift linkage without the tool
3) I could buy the tool (I considered maybe contacting the seller on ebay to see if he would let me "rent" the tool aka buy it and return it with a small payment for his trouble)
Any advice or tips would be helpful. If I don't reply to every single comment then thanks in advance. If I am mistaken or have overlooked something please forgive my ignorance, I am new to VW TDI (up to this point I've driven Toyotas exclusively).
PS I tried to post pictures of the shift lever assembly and shift linkage. I couldn't figure how to do it. They are uploaded as media to the forum, but that's as far as I got. If yall need pictures let me know and I'll try again.

 

[turbodieseldyke]

That tool has only been mentioned twice in this forum. Today, and 20 years ago.

 

[volksguy]

Hopefully some one will answer his Question.
Or have a procedure how to adjust it
First should look for worn Bushings or other.

 

[Lug_Nut]

The 'grinding gears in 1st and 3rd', particularly if R and 5th are not grinding, is not a shift lever adjustment issue. That 1 and 3 only condition I'd suspect to be worn synchronizers.

The more common 'sloppy' shifting issue is from a worn 'relay lever' that sits on the top of the transmission. The side to side movement (gate, R-1-3-5) of the shift lever is transferred to a vertical movement at this relay lever which has a guide that gets worn by the fore and aft shift lever (throw, 1-2, or 3-4). If this relay is worn the chance of selecting 1st when 3rd is desired greatly increases. Be sure this relay lever is in good condition. It's a wear item so just replace it if you have doubts.
shameless plug for IDParts

Shift Lever (A3)(B4)

Shift lever for A3 Jetta and B4 Passat....

www.idparts.com

A special tool for shift cable adjustment shouldn't be necessary.
Unthread the shift knob then lift off the plastic surrounding the shift lever as an assembly. The boot, boot bellows and surround removal allows viewing the lower end of the shift lever. The centering springs should both be in contact and hold the lever in the 3-4 gate position. Leave this lever in the N position of the 3-4 gate.
Loosen the shift cables from the relay lever and from the momentum/inertia-weight (I don't know what else to call it). Assure the relay lever can move up and down and is in the center rotation detent. Tighten the two shift cable fasteners when the relay is in this neutral 3-4 position.
Done.

 

[Windex]

For the money to obtain the special tool, I would just obtain and install the parts needed to convert the car to the later 02J shifter. So much better in either an A3 or B4.

Depending on the problem you are trying g to address.

 

[alext91]

What Windex said, but if you don't want to go that route I would try the dieselgeek bushing kit. My B4 shifter was horrible when I got the car, I could barely shift it. I got the dieselgeek "deluxe 02A bushing kit" which helped significantly. It's still nowhere near as good as an 02J shifter (especially with a dieselgeek shifter added), but I can shift confidently and reliably now. I actually found that where there is a captive nut on the fore-aft portion of the shifter, mine was completely loose which was part of why mine was shifting so bad when I first got it. I probably could have gotten away with just tightening that but I had already ordered the kit.

 

[TennesseeSteve]

The 'grinding gears in 1st and 3rd', particularly if R and 5th are not grinding, is not a shift lever adjustment issue. That 1 and 3 only condition I'd suspect to be worn synchronizers.

The more common 'sloppy' shifting issue is from a worn 'relay lever' that sits on the top of the transmission. The side to side movement (gate, R-1-3-5) of the shift lever is transferred to a vertical movement at this relay lever which has a guide that gets worn by the fore and aft shift lever (throw, 1-2, or 3-4). If this relay is worn the chance of selecting 1st when 3rd is desired greatly increases. Be sure this relay lever is in good condition. It's a wear item so just replace it if you have doubts.
shameless plug for IDParts

Shift Lever (A3)(B4)

Shift lever for A3 Jetta and B4 Passat....

www.idparts.com

A special tool for shift cable adjustment shouldn't be necessary.
Unthread the shift knob then lift off the plastic surrounding the shift lever as an assembly. The boot, boot bellows and surround removal allows viewing the lower end of the shift lever. The centering springs should both be in contact and hold the lever in the 3-4 gate position. Leave this lever in the N position of the 3-4 gate.
Loosen the shift cables from the relay lever and from the momentum/inertia-weight (I don't know what else to call it). Assure the relay lever can move up and down and is in the center rotation detent. Tighten the two shift cable fasteners when the relay is in this neutral 3-4 position.
Done.

I’ll look into that thanks

 

[TennesseeSteve]

What Windex said, but if you don't want to go that route I would try the dieselgeek bushing kit. My B4 shifter was horrible when I got the car, I could barely shift it. I got the dieselgeek "deluxe 02A bushing kit" which helped significantly. It's still nowhere near as good as an 02J shifter (especially with a dieselgeek shifter added), but I can shift confidently and reliably now. I actually found that where there is a captive nut on the fore-aft portion of the shifter, mine was completely loose which was part of why mine was shifting so bad when I first got it. I probably could have gotten away with just tightening that but I had already ordered the kit.

Thanks for tip I didn’t know dieselgeek had a store I’d just seen a couple of the YouTube videos