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VW 020 Shift Rod Bearing

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Description

Summary

In the A1 chassis, there is one bushing that is located inside a steel bracket called the shift rod bearing. It is not designed for replacement without replacing the entire metal bracket p/n 171.711.194G for the 5 speed linkage) at least until now! The 4 speed A1 linkage uses a different shape part, more of a straight bushing. One option for that is to procure the 5 speed bracket and retrofit that to the vehicle in place of the 4 speed part, especially if swapping to a 5 speed transaxle.

On the A2 and A3 chassis, there is a replacement "orange" bushing available. That shift linkage can use up to 2 of those bushings, one up front in the relay shaft bracket and another one in back at the base of the shifter housing.

These work with the 1980s vintage Rabbit, Pickup/Caddy, Scirocco, Convertible/Cabriolet, and Jetta models.
A1/A2/A3 chassis codes:
https://www.4crawler.com/Diesel/ForSale/ChassisCode.txt

The shift rod bearings up front can be replaced by drilling or grinding out the factory rivets holding the bracket together then replacing the rivets with machine screws, generally #10x1/2" or similar. The rearward bushing on the A2/A3 vehicles typically needs to be squeezed into position.
https://www.4crawler.com/Diesel/ForSale/ShiftLinkageInstall.shtml#ShiftRodBearingInstall

This part can be 3D printed in either a rigid or flexible filament such as Nylon or TPU. Or it can be turned on a lathe using material like UHMW-PE, PTFE, Delrin or Turcite. Bore the ID of the bushing then turn down the outside using a profile cutter to approximate the shape of the OEM bushing. You can use 1" dia. rod stock or 1-1/8" for a fuller spherical shape.
UHMW Rod: https://amzn.to/4sr7zRA
Teflon Rod: https://amzn.to/4slvHoZ
Delrin Rod: https://amzn.to/3L02I9v
machine screw: https://amzn.to/4pozqPQ
Lock nut: https://amzn.to/4pjZOdz

The advantage of a solid bushing with a smooth bore is that there are no delicate ribs of material to wear out over time as happens with the factory part. However, with the added surface area in contact with the shift rod, a lower friction material is needed.

The first image is an A1 style shift rod bearing bracket.
The second image is an A2/A3 style shift rod (and relay shaft) bracket.

The STL files are generated with IDclearance = 0 and ODextra = 0. You can print that first, then check the fit on the shift rod and inside the bracket then adjust those parameters up or down as needed.

More information:
https://www.4crawler.com/Diesel/ForSale/ShiftLinkage.shtml#ShiftRodBearing

Video explaining the OpenSCAD model as well as turning the part on a manual lathe

https://youtu.be/qCQdZq-mj1k

            

https://youtu.be/UwOJSUPfo3g

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