Summary

Make custom fit replacement bushings for the A2 and A3 platforms VW manual transmission shift linkage.

First image shows several pair of bushings printed in a Nylon filament fit onto a 10mm dia. bolt, similar to what the relay lever pivots on. These were all printed at slightly different dimensions for testing. These were printed in 1.75mm Nylon string trimmer line.

Second image shows a typical Relay Lever along with a bushing repair kit. The metal relay lever pivots in the pair of bushings that fit into an alloy housing bolted to the transaxle. The theory of operation is explained on the web page below:
https://www.4crawler.com/Diesel/ForSale/ShiftLinkage.shtml#TheoryOfOperation

Third image shows some typical bushings that come in that repair kit along side an OEM bushing.

The problem comes with the fit of those bushings inside the alloy housing on the transaxle, which is typically too loose. The OpenSCAD file allows you to print a bushing that fits tightly into that alloy housing and onto the shaft, plus the flange thickness can be adjusted to eliminate up and down motion of the relay lever.

Customizable dimensions are the bushing ID, OD, overall height, flange OD and height along with clearance parameters to allow fine tuning the dimensions to your 3D printer and to fit your transaxle. Best to print one sample, then adjust the clearance settings to match the printed sample. Then, once the printer tolerance is dialed in, adjust the bushing dimensions to fit on your transaxle.

Print Settings

Printer Brand:

Type A Machines

                                            Printer:                      
Type A Machines 2015 Series 1
                                                                                Rafts:                      
No
                                                                                Supports:                      
No
                                                        
                        Notes:                     
Parts are best printed in a slippery, high temperature filament like Nylon or perhaps in a flexible filament like TPU.