Club 80-90 Forums

89' 1.6TD Syncro.

Hi, It is very difficult to get first on my 'new' Doka. All the others seem pretty straight forward but 1st requires pushing the gear stick down, as if you were going to sellect reverse but pushing forward before going that far over. If that makes sense. Can be a bit embarrassing at the lights! Is there a plate/some bit that wears or is there some (easy) adjustment without messing up the rest?
Cheers K.

this is a 2 person job,get your missus to move the gearstick to the right after you have undone the clamp on the linkage underneath where it joins in the middle,then do the clamp back up and see if that helps,cj.

Another thing to check: make sure the nuts/bolts are tight at the mounting on the bottom of the transmission, on the drivers side (of a RHS!). When you are underneath the bus and the missus is wiggling the gear stick, the mounting should not move at all.

Good luck.

Andy.

Cheers fellas!

Will have to convience the good lady to jump into the dirty, smelly cockpit & give my stick a good wiggle while I have a good look at the old girls undercarriage!!

Okay, tried this today. Yeah I know really getting a move on. Everything seemed tight at the back. but couldn't get to cj's adjuster as from the front of the prop back the gear-selection rod is inside a big tube, like a drain pipe. Looked a BIG job to get any access. Is it?

er....undo the m6 bolt holding to prop protection bar and slide tube aft and lo there's the uj etc

Aidan wrote:er....undo the m6 bolt holding to prop protection bar and slide tube aft and lo there's the uj etc

Paying close attention to this thread as its a job I'll be finishing tomorrow.
Also have the same 2 section "drain pipe" covering the gear selector shaft on my 91 doka. Removing the 6mm bolt the pipe wont slide back far enough to expose the uj. What I've done is cut 2x 75mm (ish) slots each side of the smaller front section which has allowed it to slide over the rear section and now exposes the spline clamp with every thing pushed right back.
Bentleys manual says with the vehicle in neutral, release the clamp and ensure the gearbox selector lever is in a vertical position. Now at the front of the vehicle the front shift rod stop finger should be centralised in the shift mechanism housing.
A measurement of 23mm should be seen between the stop finger and finger stop on the housing. When this is attained tighten the spline clamp.
Bentleys suggest using a piece of sheet metal cut to 23mm. Just going to cut my bit now.

(chilla disappears to the garage spurs glinting in the moonlight....yeeha!)

Just popped out to look at mine! I found it right between The R' and the 3'

Hope this is of some help!

Chilla wrote:

Aidan wrote:er....undo the m6 bolt holding to prop protection bar and slide tube aft and lo there's the uj etc

Paying close attention to this thread as its a job I'll be finishing tomorrow.
Also have the same 2 section "drain pipe" covering the gear selector shaft on my 91 doka. Removing the 6mm bolt the pipe wont slide back far enough to expose the uj. What I've done is cut 2x 75mm (ish) slots each side of the smaller front section which has allowed it to slide over the rear section and now exposes the spline clamp with every thing pushed right back.
Bentleys manual says with the vehicle in neutral, release the clamp and ensure the gearbox selector lever is in a vertical position. Now at the front of the vehicle the front shift rod stop finger should be centralised in the shift mechanism housing.
A measurement of 23mm should be seen between the stop finger and finger stop on the housing. When this is attained tighten the spline clamp.
Bentleys suggest using a piece of sheet metal cut to 23mm. Just going to cut my bit now.

(chilla disappears to the garage spurs glinting in the moonlight....yeeha!)

Thanks for that, knew it wouldn't be straight forward!

Removing the 6mm bolt the pipe wont slide back far enough to expose the uj.

Chilla, if its the VW part and no-one has cut out 6" section of your truck & welded it back up, cannot see how it cannot...

but have cut 6" off mine at rear to help when putting rear bash-plates back up.

Anyway, a bit of cardboard or a guess will usually do for that adjustment.

===========================

But one way or another for both you and Karl, it's so often wear in the system elsewhere rather than that UJ (which won't have slipped), it 'usually' only when its been off that it needs re-setting, which it might have been of course...

I commend these to you to put off the crawling about bit even longer....
https://club8090.co.uk/wiki/Ge ... _improving

https://club8090.co.uk/wiki/Ge ... air_Kit_01

in other words, somethings more likely to have worn than suddenly decided to slip, fix the wear if you can

The voice of reason yet again!

Is it possible for just 1st selection to of worn as I don't have a problem with any other gear selection.

So, after doing all the necessary mine still feels tight going into 4th as it did before. Think your right HarryMann the box is a little tired. I have found though, that all other gears engage so much better now so a job worth doing.

Anyways, just run the "bout a grand dear" past the missus....didn't bat an eye ....gearbox a go-go, now wheres Aidans number

Cilla Oops

I hope you read that as I wrote it... somethings likely to be worn (in the gear selection system)...

Generally stiff selection into one gear won't be the box, if it performs well in other resepcts and is quiet.

If it won't come out of 4th or 3rd, or seems to lock in gear, then that's another matter...

If worried, then drop the oil out through a fine sieve and check the magnetic plug (replace it of course )

Very interesting HM, Ive changed the g/box oil and cleaned the magnetic sump plug which had a good 1/2" of fine metallic gearbox gubbins on it but nothing major came out. None of the gears pop out and Ive got no noises that cause concern other than the rear diff sounds a bit whiney to me but not too bad. Just this issue from 3rd to 4th and back feels tight.

Just keep an eye on it..

You should really be able to feel if it's the gate at the front (and therefore 'that' Bentley adjustment), or if it's the box.

Maybe even hear when selcting into 3/4th with engine off, again watching that detent gate underneath when selecting 3/4 should tell.

The UJ in the floor is OK I take it, lever not sloppy ther or up-spring weak/broken?