Club 80-90 Forums

Hi, I've just put a 1.9tdi in my 82 van, which is brilliant, but I have problems getting out of 4th, I have to pull over and wiggle the gear stick to eventually get it out, so I'm driving with 3 gears just in case it won't come out again. I've checked the linkage which all seems OK I can go in and out of all gears clutch in and out, but once I release clutch in 4th when I'm moving it won't come out again.

Is there an easy way of checking linkage alignment?
Anyone else had this problem?

Thanks Steve

I am sorry to report we had this issue with Vanessa's van, we had to change the gearbox.

Hi Matt, thanks but not the answer I was looking for, gotta be something else to try first and I like to find out why its not working before selling another body part to fund the van!!

Clutch release bearing? Who did the conversion?

Would release bearing not stop all gears disengaging though? I did the conversion, didn't change release bearing though

Could be the 4th gear syncro starting to break up, ideally the box needs stripping by an expert and checking. If caught in time the box can be saved, if left, the box may well be scrap

DavidPallister wrote:Could be the 4th gear syncro starting to break up, ideally the box needs stripping by an expert and checking. If caught in time the box can be saved, if left, the box may well be scrap

Would that not be difficult to engage 4 gear though?

I had trouble getting my 4 speed out of 4th gear, but would still go in perfectly OK. The gearbox was in the early stages of 3/4 synchro hub failure.

Here's a picture of the offending artcle, with hairline cracks spreading out from the notches.



Before you asume that it is synchro hub failure though, it would be prudent to check the complete gear linkage, particularly the ball and cup arrangement at the gearbox end, to make sure it's all lubed up and working properly. This is much cheaper to repair.

Thanks Colin,

I've been out tonight under the van with a new set of bushes, I've managed to change 2, bottom of the gear stick, inspected all the others and they look OK, with no play. Ive realigned the selector rods and I have a 4th that will engage and disengage, still not 100% happy, I'm gonna try and get another look tmrw, fingers crossed a bit of fine tuning and it might be as simple as that!!

Just wish I had a heated, rain and windproof driveway!!!

make sure the rod insid the guides at the box end is clean
also the cup and ball the box end needs to be clean of any dirt / old grease
a little wd40 will help at least for a short while to see if it makes a difference .

also make sure the guide plate on the gearbox is at right angles to the gearbox!

you can get 2nd so it should be in the correct place on the box!

presume when you fitted the engine you removed the gearbox ? and at no point did you EVER leave the box supported / loading the gear rod?

Watching with interest, may be worth fixing our old gearbox to resell.

When was the gearbox oil last changed?

May be worth whipping out the drain plug (make sure you can undo the filler plug 1st though) and seeing how much debris is stuck to the plug magnet.

Slightly furry is normal, but any ball/roller bearings or sections of cage/syncro stuck to the magnet will tell you all you need to know.

billy739 wrote:
presume when you fitted the engine you removed the gearbox ? and at no point did you EVER leave the box supported / loading the gear rod?

I chocked up the box although it was lowered when getting engine out and in, im just about to sort tools and have another look.

Gonna check gearbox oil as well

Will report findings later

So the story goes on....... I got the teenager out of bed and got him to wiggle the stick in neutral then followed the connecting rods along to the box, found play in the end of the rod where it goes onto the pin mount, hope that makes sense... The rod is hollow and on the end of the pin is a collar that holds a silicone doughnut, bush type thing, this was there but not on the shaft, I put it on and it came off again when changing gear, so I improvised, eletrical tape and grease!! Slides in and out nicely, it'll rule out alignment anyway, all gears change on the drive
Test drive later........

so your running the original dk box with early selector?

check that the pin with the donut is straight , as they are meant to be!