Sticks in 4th

Post by **cumbriankeith** » 19 Apr 2006, 08:50

2 litre a/c CU engine with standard DK code 4 speed gearbox.

Having had the engine/gearbox out recently the shift rod has been off, refitted with a new rubber boot - done about 2k miles since.

Sometimes after a few or more miles in top (ie 4th) it is really reluctant to come out of gear. All other gears seem fine and coming out of top is often no problem at all. So what can be the prob? I've looked thro the Wiki to no avail - there's lots on reluctance into 2nd but nothing about getting stuck in gear.

I've tried adjusting the shift rod (this should be slightly eccentric, shouldn't it?) but either it isn't that or I haven't got it right yet. I renewed the gearbox oil a couple of years ago but haven't checked the level for a while, which I can do easily enough - but would low oil cause sticking in gear? The box was professionally rebuilt a few years ago so internal wear should be unlikely, shouldn't it?

All ideas welcomed... please/thankyou...

Post by **Horney** » 19 Apr 2006, 09:20

I have the same problem with 4th and sometimes 3rd too. I find a quick wiggle before changing down sorts it, took a bit of getting used to.

If you find out what the problem is I'd be interested to know too.

Sorry I can't actually help!

Nick

Post by **Horza** » 19 Apr 2006, 10:00

Ditto.

Only seems to be after lots of motorway miles and in my case the problem is mainly in 5th but once it's doing it it also needs more effort coming out of 4th and 3rd and possibly other gears. After I've been for a wee at the service station it's fine again.

I can't even decide if it's the linkages or internal to the gearbox. I would appreciate any pointers on this.

Post by **germman** » 19 Apr 2006, 11:09

just happend to me BE WARNED one day it wont come out at all ...
it turned out to be 4 th gear had broke and although its held in place its got a crack right across the gear , (shiplake dave showed me it !)
so it may last for a while but eventualy when it cracks the other side of the ring gear then it will jam in place and nothing will shift it , 200 quid for a re build ... ring dave at shiplake motors and talk to him hes used to the transporter gearbox and hes a freind of thomas diamondhell 0118 940 3125 or 0118 940 1331 tell him you with 80-90

Post by **Horza** » 19 Apr 2006, 11:16

Oh no, no no no!

I have no other vehicle to get me to work, I can't afford gearbox failure

Post by **Cate** » 19 Apr 2006, 11:43

This sticking in 4th after long hot runs happened with both my vans, I can't understand why it should only do it when it is hot. The previos van did get stuck in 4th and a good clean up of the links solved it for some while but still reluctant to move after long run again.
Is this just a 'feature' of these old vans or is it definately the cog going?

Post by **purpletony** » 19 Apr 2006, 14:17

this happened to my mates van
where the lever comes out of the box and locates in its socket
the lip on the top edge had broken away so i put a wide jubilee clip around it and gave it plenty of grease and it worked and ran purfik

give it a go it worked for me

Post by **cumbriankeith** » 19 Apr 2006, 14:45

Tony, Tony oh purple one!
Not sure which bit you mean exactly - sorry to be dense...
Do you mean the shift lever with the "plastic onion" or something else?
Lip on the top edge of what?

Post by **Ivorblueun** » 19 Apr 2006, 15:26

check the linkage when it happens, reason being i had a similar problem with mine recently in second and fourth turned out to be the ball on the gear shift lever at the gearbox rotating out of the cup then jamming against the edge of the cup when trying to move the out of those gears. thought initially it was because the rear linkage wasn't far enough over the splined end of the front linkage as had removed it all to replace bushes and boots and gators turned out that the collar on plastic ball had gone soft allowing the ball to move up hence it coming out the cup.

Post by **cumbriankeith** » 20 Apr 2006, 07:21

Well it happened again on my way home from work yesterday so I investigated more last night. The linkage does not seem to be at fault - there's no undue wear or deformity of anything. Moreover the shift lever/bracket that is splined/bolted onto the gearbox got "jammed" in gear a couple of times while I was wrestling with it. Looks like it may be more serious...
I may be looking for another box. Anyone got one? (2 litre a/c DK code)

Post by **germman** » 20 Apr 2006, 19:56

i have 2 keith ...both with the same prob , bettewr get your rebuilt ,or if you need one

Post by **andysimpson** » 20 Apr 2006, 21:10

I don't know of the cause of this or the cure but this is a widespread problem accross the older vw range, beetles, polo's, some golfs, bays, splitts, t3's. Alot of them did it from new, my beetle has done.

Post by **cumbriankeith** » 21 Apr 2006, 14:00

Checked the level last night and it needed virtually a litre to top it up - this alone wouldn't cause it to "jam" in gear would it??

(wanted! DK code box with Hyd clutch fittings - there's a 1600CT cable clutch one in Blackpool on eBay at the moment)

Post by **Louey** » 21 Apr 2006, 14:30

i'm guessing less than required oil will cause overheating and therefore damage - just like if the engine oil level is too low.

just a thought.

Euan, give me a ring

Post by **Ivorblueun** » 21 Apr 2006, 18:28

yep if the oil was low and a litre is about 20% then things are likely to over heat causing expansion and and so start to bind up

Club 80-90 Forums

Sticks in 4th

Sticks in 4th

which bit?

Oh dear

Oil level