Club 80-90 Forums

After driving around for the last four months with gerachanging problems I decided to taker a closer look...
My problem was difficulty in getting third gear (5 speed) especially when changing down from fourth.
The problem was that when I serviced the shift rod mech I put on a rear gater which was not present before, and this was the cause of my problems.
When in third gear the linkage rod is pulled forward and the gap between the end of the gearbox bracket bush and cup holder was not long enough to compress the gater, thus me having to yank it in.
Now my question is why was this happening?
I have had the whole thing off and cant find any reasonable wear that would cause this.

You have re-installed the rear bush carrier plate the wrong side of the gearbox lug I expect...

No its deffinitely on the right side thats the First thing I thought of.

When in third gear the linkage rod is pulled forward and the gap between the end of the gearbox bracket bush and cup holder was not long enough to compress the gater, thus me having to yank it in.

1) You've used the correct bellows/gaiter?
2) They're correctly fitted within the cups?

[img:800:600]https://club8090.co.uk/wiki/images/Selec ... 800%29.jpg[/img]

It can't cause a problem on yours and not on 1,000's of others... if its' the right part fitted in the right place, surely?

3) Look closer?

It's possible the slop on the ball/socket joint is that bad that rod has to move further

Also ensure the socket/cup is not moving at all on the rod (rocking back or forth) and that the roll-pin is a very tight fit in the socket/rod and no play exists...

Hi there HarryMan.........
Are you saying that the belows should be held in place by the bush cups?
I did try this originaly but found it very difficult to put it all back together so left them floating.
I will get a new one and sort it out next week if thats the case.
I am also having problems tring to find a new nylon reverse stop......
I purchased one from VW but when it arrived it was completely different and looked nothing like the one in tha VAG catalouge.
I now have VW tec team in Germany trying to figure it out.
Good old Cord Wallis group, they bend over backwards for me.

[IMG:800:600]http://i49.photobucket.com/albums/f283/ ... 010006.jpg[/img]

Yes, I think they are lipped inside the bush retaining cups, before clamping up the new nylon bush (E part no) then whole thing filled with grease, bellows'n'all, and slid onto shaft up to a fwd retaining clip, a crimped clip normally. Nothing at rear before socket goes on and roll-pin drifted in from below... the bush assembly bracket then bolts to front face of gbox lug.

before clamping up the new nylon bush (E part no) then whole thing filled with grease, bellows'n'all

Thats what I did, and thats why I found it so difficult the bloody thing kept moving all over the place.

Any ideas on replacing/sourceing the nylon guide....I saw you glued yours back together, I tried that and have now lost the bottom half.
I have a feeling the VW tech team will come back and say obselete.
Rob.

Thats what I did, and thats why I found it so difficult the bloody thing kept moving all over the place.

Still not sure of problem, clamp up dry and then grease maybe?


One I did but the other I made from Tufnol, as you can see, that wasn't easy at all, slotting it out! Didn't last too long either when gear lever bashers got to drive it...

However the one you show looks maybe easier, or modified somewhat, little chance when mine were on end of gear-lever's fork; looks like you could rivet a piece of nylon to a steel bracket, flush (csunk) rivet ? Or a slab either side and through rivet (bond as well).. but a 2md hand gate-box might be best

Some kitchen cutting boards are made from nylon I think, a small herb chopping board maybe? It hacksaws OK. Doesn't file OK, unless using millenicut or dreadnought type (like used for bodyfiller)...

Is yours a late bus as my peices on the front end of the shift rods are of a plastic push on type and pretty soft really.
The peice I am refering to is in the photo although it does look remarkably similar to the ones you have on the front end of your shift mech.

Those Wiki pics are of my Diesel syncro, which I'm sure are different... think the fork has the buffers, instead of the gate/detent-box

Been thinking of just lining my fork with copper, brass or ally buffers, which can be fastened really well (csunk hand-set rivets) and just sod the clashing noise... accuracy of gate would be good though!

[img:663:648]https://club8090.co.uk/wiki/images/Gear_ ... ssy_01.jpg[/img]

A higher resolution picture of the area of interest

Perhaps you should for now, just space the bracket fwd of the gbox lug with some thick washers or a couple of nuts.. see if say 1/4" does the job, and then work out the problem later...

Is it possible your gaiters look longer than mine?

The original setup didn't have them and used the 251... ... ... D part no. bush as used under the centre of the van, just ahead of the selctor-rod UJ (see Wiki)

Yes they look the same as yours I got the part No's from the wiki entry...
Will the ones for the rear fit the centre also as I havn't got one there either.

No bellows at the front (midships), just the ... ... ... D part. no bush, which was the early fitment at the rear (without the bellows)..