Club 80-90 Forums

Hello,

We have been taking a look under the T25 today, trying to work out what is happening to cause a squeaking noise during every gear change.
After a moving the Gear shift rod from underneath, we've come to the conclusion that the rod is sitting too low and rubbing on the top of the petrol tank.

It would seem there's something missing here (shown in the photo below), the camera is aimed following the rod into the area where the petrol tank lives.



VW Heritage doesn't show anything obvious that will fit, the lower assembly shown in the link below.

It would seem a number 9

http://www.vwheritage.com/vw_act_page.r ... try_GB.htm

4 Speed early T25

Any help will be greatly received and appreciated

In your link to VW Heritage, only the bottom parts diagram is relevant to your early van, so part 9 is not relevant to you. This is the full mechanism for a van of your year:



Part 21 is the only bush that supports the centre shaft (32) through the chassis above the fuel tank, and they aren't available (unless anyone knows otherwise). The universal joint bushes (4 + 22) do seem to squeak when they dry out. These bushes aren't available either, I think, but if they aren't worn you can pull them apart, get some moly grease into them, and they should stop squeaking. It's not that hard to get the early shift rods out, using the procedure in the Haynes. Then you can get at the bits you need. The only problem is that, to get to the chassis bush (21), you'll need to take the fuel tank out first.

It can't really drop to rub on the top of the fuel tank because, even if the bush at 21 is completely knackered, the hole through which the gear linkage passes isn't much bigger than the bush. It would just put a bit more slack into the system, that's all.

I've got some pictures of the real joints close up, if that would help to explain it better.

James

Hi James,

That's a great help, the high res photos will be appreciated.

Here's the front shaft/centre shaft joint:



You can see one bush (no. 4 in the diagram) on the right-hand shaft. The other bush (22) is inside the tube. The ball joints on the end of the front shaft locate into those bushes. Some moly grease in these joints should stop them squeaking. The centre shaft passes through a bracket in the chassis just to the right of this joint, and this is where you'll find bush no. 21, which is possibly the cause of your problem. These parts are all above the fuel tank.

Here's the assembly just under the gearstick:



There are two bushes (14) inside the base of the stick itself, which can wear. This is the other end of the front shaft from the ball joints in the photo above.

Edited to correct part no.

Hi James,

Great images,

This gives me confidence to take a closer look to check the bushes etc.
I'll let you know what I find.

Thank you,

Leonard,

Hi,

Any recommendations for brand suppliers of moly grease?

I bought mine from here:

Ebay Linky

Does this mean that you have it apart, or are you just getting the grease in readiness for the big day?

James

Hello,

Very good photos RedGus..

On my way back from Le Mans.. I got the dreaded worn bush drone..

The van drives fine..

just sounds embarassing ...

Question.. on the inside of the tin box gear shift cover.. do you have a plastic plate held in with 2 plastic 'blibs',,acting as a distance plate/slider...

Photo of this would be great please ...

Appalling picture in Haynes..

Cordialement,

sarran1955 wrote:Question.. on the inside of the tin box gear shift cover.. do you have a plastic plate held in with 2 plastic 'blibs',,acting as a distance plate/slider...

Photo of this would be great please ...

Do you mean Part no. 10 in this diagram, on the opposite side to the reverse stop?



I'm afraid mine is missing too, and there is an annoying "donk" when the base of the gearstick goes over that way.

I have been thinking that it couldn't be that difficult to make up something in an appropriate plastic, as nobody seems to have the real part available any more. What do you think?

Oh, and thanks for the photo compliments!

Cheers,

James

Hello,

RedGus wrote:
I have been thinking that it couldn't be that difficult to make up something in an appropriate plastic, as nobody seems to have the real part available any more. What do you think?

I quite agree.. and as I am going to drop the tank.. then I want to get all the work done in one go....

I was thinking of a rectangle of polypropylene thick enough to take 2 countersunk screws..

Do you have good photos of the linkage to the gearbox please

Dimensions...

Cordialement,

sarran1955 wrote:Hello,

RedGus wrote:
I have been thinking that it couldn't be that difficult to make up something in an appropriate plastic, as nobody seems to have the real part available any more. What do you think?

I quite agree.. and as I am going to drop the tank.. then I want to get all the work done in one go....

I was thinking of a rectangle of polypropylene thick enough to take 2 countersunk screws..

Do you have good photos of the linkage to the gearbox please

Dimensions...

Cordialement,

Hello John,

That was roughly my thinking with the plastic buffer strip, but I thought it might be best to bolt through the existing holes in the metal protection box, and counter-bore the heads on the inside, so that the mechanism doesn't foul the bolts. It's not too difficult to get at, once the spare wheel is out, so I'll probably just do an experiment. If you do one as well, we can compare results.

I have some photos of the rear gear linkage shaft (13 in the diagram), and the locating pin (17), but none of the actual connection at the box itself (23). I'll dig them out and post in a while. I found that only the top plastic "ball" on part 23 was worn, the one that takes the sideways movement, and consequently all the sliding back and forth too. I didn't fancy spending over £40 for a complete new part, when only this ball was partly worn, so I'm trying to come up with a CovKid-style home repair.

Cheers,

James

OK, here is the gearbox end of the rear linkage shaft (the locating pin goes in the hole):



The same from the top:



And the locating pin, mounted to the front of the gearbox, that goes into the end of the shaft. I've replaced the crinkly bush (26 in the diagram), which was knackered. Both the bush and the rubber bellows are still available.



James

I will take a look to see what it happening under my Van over the weekend.

If between up we can work out a substitute part for No 10, then we'll all benefit.

Sorry to hijack this most excellent thread, but where can I get a new guide pin (17) from?

These pins, are they suppose to be straight or bent?