VW - A1/A2/A3 Relay Shaft Bushings

Make custom fit replacement bushings for the A1, A2 and A3 platforms VW manual transmission shift linkage.

First image shows several variations of of bushings printed in a Nylon filament fit on an A1 relay shaft, along with an OEM molded polyurethane bushing on the right. The center example is sized to match the OEM bushing and the left example is a taller version. The A2 and A3 relays shafts are similar except that the lever is in the middle of the shaft. These were printed in 1.75mm Nylon string trimmer line.

The theory of operation is explained on the web pages below: https://www.4crawler.com/Diesel/ForSale/ShiftLinkage.shtml#TheoryOfOperation

We've also turned these bushings on a lathe out of oil filled UHMW and Teflon rod stock: https://www.4crawler.com/Diesel/ForSale/ShiftLinkage.shtml#RelayShaftBushings Material like Delrin or Turcite would also work. For turned bushings, use a small (#4x1/2") screw through the flange to keep the bushing from spinning in the bracket.

The long arm of the relay shaft rotates side to side as the main shift rod pushes and pulls on the short lever at the base. You need tight fitting bushings to hold main shaft vertical and only allow it to rotate. Any slop in the bushings will let the shaft tip and cause loss of shift linkage motion. Lose too much of that motion and you'll have trouble reaching all the gears in the transaxle.

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 relay shaft and bracket. 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 vehicle.

Related parts: https://www.thingiverse.com/thing:6915558

Print Settings

Printer Brand:

Type A Machines

Printer:

**Rafts:**

No

Supports:

**Filament:** 1.75mm string trimmer line Nylon or TPU n/a

Notes:

Category: Automotive