Hard to find first gear

[Chilla]

Ok cheers HM for the info will have a closer look at linkage etc
Thanks!

[Chilla]

Bump this one back up with a bit more info-

Have been in touch with my local VW dealer (murrays, plymouth) about getting hold of the gear lever shaft bushes code 251 711 207D.
Apparently, there were only 8 left in stock when I bought my 2 and would go obsolete when sold.
The 2 rubber bellows/gaitor at the rear bush 251 711 167F is now obsolete.
Any ideas of anything else that may fit?

Also, can anyone tell me- the vertical lever that fits onto the splined shaft that goes into the gearbox, has a ball one end that fits into the cup. Anyone know if the ball has a covering or not? Seem to remember reading somewhere that it had a Vinyl (similar) coating. Mine doesnt and appears to be metal on metal.
Thanks in advance

[HarryMann]

The only ones I have seen are a yellowed nylon, so unless this is a very early design, I don't think so...

I think the nylon ball can be removed though, but isn't listed as a separate part...

[Chilla]

Thanks HM
Vehicles a 91 but somebodies obviously been at it in the past, broken and welded gear change lever proves someones tried pretty hard to get it in gear.
Could you give me an idea on what kind of tolerance there is between ball and cup?
Cheers

[HarryMann]

Sloppy, you could probably get a 25 or 50 thou feeler gauge at either side of ball in the plane in which it works.. for a typical one.
The cup wears a lot inside and develops an edge at the top, so its convex... but it does make the change a bit sharper to marry up a good cup with a reasoable ball..
Sounds like a 2nd hand arm is worth getting hold of, and there are still some new ones about I think

[Pete Nice]

I went to test drive a van & that pops out of first gear. It doesn't do it under load, more when you back off again.

Not sure it that would be linkage or gearbox? Nothing looked bent or twisted in the linkage.

I haven't bought it yet.

[Chilla]

Sloppy, you could probably get a 25 or 50 thou feeler gauge at either side of ball in the plane in which it works.. for a typical one.
The cup wears a lot inside and develops an edge at the top, so its convex... but it does make the change a bit sharper to marry up a good cup with a reasoable ball..
Sounds like a 2nd hand arm is worth getting hold of, and there are still some new ones about I think

Thanks for the info again HM. Think I'll look in to getting a new lever and cup. Hopefully getting front repair kit and bushes through soon so will bump this one back up when fitted.

[KarlT]

Good to see the old thread back again.

Have just got used to my qwerky 1st selection now.

Have been on to VW vans today, had a lovely flirt...sorry chat to Amy. Just to be aware that Syncro has different front-end part numbers to regular vans.

I guess to-do with the crawl gear.

[HarryMann]

Some are some aren't I think..

The lever pivot repair kit is the same.

[Reco]

Re 1st selection problems.

Had similar problems with 1st gear on my pick up when first got it - for first month or so was a bugger to get in and thought it was in need of adjustment/a bit knackered. Many embarrasing moments at traffic lights- used to start trying for it as soon as stopped and hold clutch down till green. I even selected revrse on occasion!
Then my son borrowed truck and had no problems
Turned out it was me -you really needed to be precise with this one {Never had any problems with my van}- move stick right across then up at a right angle without any forcing and has worked perfectly ever since!!

You may be as lucky and need to fix your selection technique rather than the box!

[HarryMann]

If it inadvertantly selects Reverse without depressing the lever first, then the detent gate and/or the nylon sheathed tabs on the lever's fork are worn or broken - yes technique can generally get a round it, but it is worn more likely than maladjusted, though that is a possibility.

[Reco]

I'd pressed down gear stick in all the fiddling about to get it in -no problems now.

[Aidan]

someone on ebay is selling kit of leverball, and both nylon bushes for the rods for £20 ish, real good value. JK were also selling these parts, I haven't checked recently.
Brickie will hopefully have them from source too soon. I've only one set left and i'm keeping them for mine long term, have got second hand leverballs if yours is really foobarred, generally they aren't, but the steel part rusts and can blow the nylon as well as bad wear in the cup, a little lube is a good thing : )

[Chilla]

Update as promised,
From the front- Ive changed the gear lever "onion" with a new kit from VW
Then I split the shaft at the spline and hauled it through the front to re-mould the nylon sheaths on the shaft fork. I used masking tape for the mould and poured in some aroldite which I filed down to the right thickness...works a treat!
The front nylon bush and housing(s) were worn/corroded due to all the crap which was thrown through the front protection tube ( mine was minus its gaitor) there was about 2 inches of sand in the tube which grated through the bush every time I changed gear. Changed the bush, cleaned the housing and made a new gaitor.

Pulled the rear shaft out emptied about an inch of sand out of the cup and removed the rear nylon bush which was ovall in shape. The cup was also ovalled mainly on one side so I put in a thin .75mm aluminium liner bonded in with my favourite aroldite. Replaced the bush, reversed the cup put on a new gaitor and bolted it all back up using the 23mm bentleys measurment at the front fork.

Result- Absolutely stoked, can get any gear when I want it even when the box is cold.
Findings- If the old gals transmissions getting a bit sloppy get a new bush for your shaft. works a treat

[HarryMann]

Triffic stuff... esp. reversing the cup, which I did too...

araldite job..

works a treat!

I just hope for a reasonable time, let anybody else drive it and guarantee it'll soon get knocked off

So nice to have a chang that selects... after years of falaffalling around and ramming vehicles behind at lights