Won't stay in 1st, 3rd and 5th Gear

[Andyvandy]

Hi,

My friend Cath has a 1985 1.6 Diesel tin top camper with 5 speed gearbox.
After the local garage removed the gearbox to fix an oil leak several gears will no longer stay selected.
The 'top range' 2nd, and 4th select Ok but the 'bottom' Ist, and 5th will not stay in gear. She has to hold it in gear with the gearstick.
The VW garage in Lossiemouth reckoned she needs a new gearbox which doesn't sound right given that the box and selection was OK before the box was removed and refitted.
It sounds more like a worn/badly adjusted linkage?
Does anyone have an idea as to what the fault is and how it can be fixed?
Also anyone know pf a garage in Scotland which is qualified to do the work?

Thanks

Andy

[Mocki]

sounds to me that they put the linkage holder on the wrong side of the flange on the gearbox, making the selections 10mm out, which is about enough to "cock" the job up.........

[Fritz]

Bloody heck you are far enough North,,,,,

I can't suggest any local garages to you with VW experts, but I'd be trying to contact either one of the guys at Syncronutz (Shotts);;;;;
http://www.syncro-nutz.com/

or our resident Gearbox expert 'Beaker'. ;;
http://www.aidantalbot.com/

Regards

Fritz,,,,,,,,,,

PS, I have to agree with M0cki, by the sound of things they may have taken the gear linkage apart to remove the gearbox and then forgot where it was positioned.

[toomanytoys]

Yeah I think they talk bowlocks.. they fooked it up so they should fix it... IF you now trust them... As said, sound like they have not refitted the linkage correctly... Muppets.....

Syncronuts would be my first port of call.. much closer than Aidan....

[Aidan]

I'd be certain it's the rear bush plate fitted the wrong side of the cast bracket, two bolts, five minutes yourself to fix, 13mm spanner and a deep 13mm socket or 13mm socket on an extension. unless the van is lowered you can do it on the floor no garage required.
Check also that the gaiter on the ball joint is properly fitted to encase the cup and kep the dirt out, as if it's all bunched up on top it can act as a spring being rubber.

[Syncro G]

Humm, I've got a simular problem with my van thats causeing alot of headscratching. Only jumps out of top though, all other gears work fine and select pritty easilly. Seems to go into top gear nicely and fully, but as soon as power is applied to it the leaver is fired into neutral unless you hold it there. Swapping the secector rod in the top of the box for one with more posative detent springs has made the gears more defined but hasn't 't helped it stay in. I'm sure on the old box the leaver used to be sprung to the right of neutral, in line with 3rd and top. Doesn't seem too fussy where it sits in neutral now though, would that mean anything?

[Aidan]

Glen I think you will find the dog teeth are worn on the load side, once it starts coming out it will carry on doing it. The teeth will be nice and sharp so engages nice , just like VLux's did.
Also the main bearing may be moving in the case allowing the mainshaft to move under load, could be a combination of the two, it's a strip it and check it out job, nothing to do with selector I reckon.

[Syncro G]

Glen I think you will find the dog teeth are worn on the load side, once it starts coming out it will carry on doing it. The teeth will be nice and sharp so engages nice , just like VLux's did.
Also the main bearing may be moving in the case allowing the mainshaft to move under load, could be a combination of the two, it's a strip it and check it out job, nothing to do with selector I reckon.

It is soon to be reopened, but the MOT is comming first. Interestingly it has done this both before and after having 4th gear and the synchro unit swapped with another, both thought to be good. Bearing sounds possable as that stayed the same for both gear sets then but thats new too.

Is this ware very obveous or can it be quite subttle to cause problems?

[toomanytoys]

Aidan will give a far more reasoned explination, but yes, the tolerances are so tight in all T25 boxes as soon a there is a little wear they start to cause problems and eat themselves...

Parts are getting harder to find.. so dont keep driving a box that has started to have issues.. it wont take much to make it scrap.. Aidan has show me loads of parts that have been eaten coz the box was driven and driven until it wouldnt go any more...

[HarryMann]

sounds to me that they put the linkage holder on the wrong side of the flange on the gearbox, making the selections 10mm out, which is about enough to "cock" the job up.........

Mocki and Beaker are right I should think, being even gears that select and odd ones that won't...

Could AndyVandy confirm he's read this and passed the information on please...

[Andyvandy]

Thanks for all the help Guys.

My friend Cath is here now and amazed at the response from you guys.

Thanks for all the help and I will Let you know the outcome.

Andy

[Aidan]

Glen,
it's subtle, I have to admit I missed it on Vlux's (twice ), now it's lesson learned.
The 0.78 TD gear seams to be the most susceptable to it, nothing to do with the gear I think but to the TD's torquey ability to pull it from lugging to full revs, you can't lug a wbxer like that so you change down and take away the high load. 1.9 TD makes it worse obviously.
It's why I haven't got any 0.78 gears in reuseable condition, in future will have to substitute the Albins 0.77 at a cost of £260+, or up the ratio to the 5 speed 0.82 which is not ideal especially with a 1.9TD or mTDi or TDi

[Andyvandy]

Well Guys,

It was the linkage that was incorrectly fitted as you said!

Another garage re-fitted it and all is now OK.

Cath and Beth (her daughter) can now set off for their new home in France in the next couple of days!

Thanks again

Andy

[CathandBeth]

To Mocki, Fritz, toomanytoys, Beaker and of course AndyVandy and all who helped SO much with this - the biggest thanks EVER! EVER!
Having been sneered at by yet another garage today I went back to the ones who said new gear box, ARMED,literally with your informaton and Lo and Behold - yes in about 5 mins - they said yes it was the fact that the other garage had put the linkage holder the wrong way around on the flange on the gearbox, it is now a pleasure to drive they said. Afew days ago they said go get a new gear box and come back then.. In direct proportion to the OBSTRUCTIVENESS of local garages I am amazed by the help and commitment of all you guys out there, you came back so fast with such in depth and accurate, detailed help and support I can only say Greatest Thanks Ever. I can now move to France with my 6 year old and all I have to worry about is - um - I hope - driving in France!
Very big thanks indeed
Cath, Andy's friend