gearbox or linkage

[paddy1960]

Aaaaargh
waiting for the AA to relay home

driving along - some difficulty in gear change. managed a few but eventually unable to select any gear at all, not completely in neutral as some noise of not quite meshing gears when clutch fully released - but no drive

bushes at bottom of gear lever appear to be knackered, plastic cup dislodged from tom and lever now moves 2 cm up and down.

I suppose I am trying to be optimistic that this is a linkage failure that has caused the gear selection failure and not the gearbox itself.

can i select neutral at the gearbox without using the linkage? If so how?

I am assuming that its worth replacing the bushes etc and seeing if that helps cure the problem before I look at the gearbox on the basis that I would have to do this anyway - any thoughts?

[Aidan]

with the linkage off the ball on the end of the selector shaft should be able to be moved freely back and forwards in each plane and the whole shaft slides in and out of the box to select which plane it's in
1st/reverse is furthest in, then 2nd/3rd, and furthest out is 4th/5th
sounds like you may have a spigot bearing issue, see if you can select the gears with engine off, then sort the linkage, nb get the boot for the cup and ball it really helps to keep it clean and lube present doing it's job

[paddy1960]

Aidan thanks for the advice -excuse the ignorance but...

with the linkage off the ball on the end of the selector shaft

- not quite sure where you are suggesting separating from the linkage - I have attached a picture from "Bentley"

-?am I looking in the right place - this is the set lever/shift lever dropping out of the gearbox?

I can't see how the lever with the ball is attached to the shift lever and how to separate? Do I need to dismantle the rear bushing/support plate to drop the linkage and release the ball?

ps what lubrication do you recommend for the ball joint and other bushes in the linkage?

thanks again

[Aidan]

yes that's it drop the support plate off the box
originally vw use poly grease as it's a nylon/ali thing but it goes hard over time.
I use a thumb of moly grease, cv grease that is
if you are replacing the rear bush you have to remove the cup from the shaft, so easy to clean it all up then
when refitting offer up cup to ball, pull boot skirt down over cup, fit plate to box loosely and then push the whole lot up gently and lock off the bolts on the box in that position should be right

[paddy1960]

I've dropped the linkage off and tried to select gears using the shift lever at the box - not quite sure what to expect but, only get bit of movement but definitely not a clean selection of 5 gears.

Is this definite proof of a box problem or would jacking up a wheel and jiggling it about a bit possible release something that is currently in an awkward position? Naively hopeful!

if it is the spigot bearing - this sounds expensive - whats the solution - any idea of cost?

Thanks again for the help Aidan

[Aidan]

if you can't select any gears easily with the linkage off, about 1/8th rotation in each direction forward or backwards with positive engagement, then suggests a problem on the input side or some other fault. Is the selector rod in the centre position with ball at bottom and able to push in and out of the box against spring pressure ? if it's not in this position then it's stuck in gear.
If not stuck in gear but no gear engagement jack a wheel in the air and box in neutral (central position free to move in and out) with hand brake off try and turn and turn the jacked wheel it should be possible, if it's not the box is jammed in gear(s) or synchroniser jammed/failed or spigot bearing failed seized on.

[paddy1960]

I'm back at work tomorrow - so will have to try jacking it up and moving the wheels, later in the week.

the selector rod is not quite vertical and won't move in and out of box by more than about 5mm, possibly moves forward by about 1/8th of a turn but not by the same amount in the opposite direction.
How far should the in/out travel be?

With the engine running and the clutch released fully the van wasn't in gear (well it didn't move anyway) although you could hear some cogs/shafts spinning more noisily than was normal for neutral.

assuming no miraculous release of something internal - is this a job for a gearbox specialist or is it possible for a local garage?

Anyone know of a good one of either in reach of SE London? Unfortunately warrington seems a bit too far Aidan!

[paddy1960]

Now had a chance to jack up the van, results are;

wheel moves freely (clutch engaged)

even after jiggling wheel a bit gear selector at box still has same limited movement and can't select any gear positively

tried to get selector into what seemed as close to a gear being selected - started engine, released clutch - no drive


I am assuming that this is now box out time and possible vw and/or gearbox specialist

anyone got any recommendations in SE London area - now got dead van with no drive so close proximity would be helpful.