

| Subject: | Transmission shift linkage adjusting |
| From: | Dave Katsuki |
| Date: | Mon, 5 Jun 2000 00:43:01 -0400 |
While I'm thinking of it, thought I'd document my efforts in adjusting the shift linkage on our 90 Westy. After I had the transmission replaced (low mileage unit from junkyard) recently, it was hard to get into first. I needed to depress the know and move it slightly into the reverse gate to get it into first (but not second usually). Since this seemed like a simple adjustment, I just loosened the coupling in the shift rod (after carefully marking the original position), and moved the lever at the transmission end slightly toward the reverse side, and then tightened it. What could be easier? Unfortunately, it still needed to be pushed slightly into the reverse gate to get into first. So a little more adjusting in the same direction. Needed still more. Adjusted a little more. Now could get into first, but couldn't get into reverse, and third was funny. Arrrghh! Finally in desperation, I decided to follow the adjustment procedure in Bentley exactly, and wonder of wonders, ALL the shifting problems went away! Perfect shifting, and has remained that way for the last 500 miles! Here's what I did, folks: Bentley calls for a 23 mm spacer (several different sizes, depending on the year of your van), and they suggest metal, but I made a 23 MM spacer by sanding down a 1/4 " thick piece of wood to be as close to 23 mm wide (parallel & vertical sides) as I could get it. I suspect +/- 1 mm is fine. The piece ended up being 23mm by maybe 30 mm with a short handle. Length isn't critical. but I wanted something to grab. Then jack the front of the car up as high as possible and take out the spare. Loosen the coupling on the shift rod. When you get under the front of the car with your back in the spare tire carrier and your head as far up as possible, you can just see into the open end of the shift housing (where the shift lever comes down). Try to get the end of the shift lever roughly centered front to back in the shift housing. Now place your precision 23 mm (or other appropriate sized) spacer between the end of the shift lever and the stop (right side, looking toward the front), and then tie a wire or string around the shift rod and the nearby radiator hose, to keep the spacer in place. Scoot around under the middle of the van and make sure that the shift lever at the transmission end of the shift rod is vertical, and then tighten the coupling. (Make sure the spacer didn't drop out during the tightening.) Take the wooden spacer out and check the shifting. This took me about 10 minutes after making the spacer and jacking the car up, and it was perfect the first time! Couldn't believe how easy it was. Dave 90 Westy
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