Hey Al,
I suspected this was the case.  I have read the Bentley description, but
there's a step in there that doesn't make sense to me.  With a new rebuild
on the tranny, I want to get it right.  Does anyone have a slightly better
discussion of this adjustment than the Bentley?
tx,
bmc  :)
"Faith will move mountains, but you'd better bring a shovel...."

> From: Al Knoll <al_knoll@PACBELL.NET>
> Reply-To: Al Knoll <al_knoll@PACBELL.NET>
> Date: Wed, 27 Feb 2002 18:56:43 -0800
> To: vanagon@GERRY.VANAGON.COM
> Subject: Transmisison / Shift Linkage adjustment
>
> Sorry if this posts twice.  My ISP/mailer is higgledy piggledy just now.
>
> A note on proper alignment/adjustment of the linkage.
>
> Fastidiousness, and attention to detail is mandatory in adjusting the
> linkage.  I recently paid ~1200USD to have my syncro transmission rebuilt by
> Transaxle Engineering in Chatsworth, CA.
>
> The first installer, not Transaxle Engineering but another outfit, neglected
> to check the linkage for proper alignment and adjustment after installation.
> ~1000 miles later, the transmission began to pop out of 4th gear when coming
> off power.  It happened maybe eight times before I went by my local VW
> wizard, Larry'Z Auto Works, here in Sacramento.  Larry pointed out the flaw
> immediately and provided guidance for a temporary remedy that might allow me
> to drive the 350miles to Chatsworth.  Unfortunately, the damage was too
> extensive to remedy.  I drove the distance in 3d gear at a somewhat
> leisurely pace.
>
> The problem had to do with the linkage binding due to an improper adjustment
> and not allowing the necessary 'float' at the rear shift rod bushing. This
> misadjustment caused 4th gear to only partially engage.  The result was a
> worn-out gear set.
>
> This adjustment is covered in detail in the Bentley and I can provide the
> specifications in .pdf format to the alternate vanagon list for your
> perusal.
>
> Jeff Field at Transaxle engineering honored his 12 month internal parts
> warranty for labor with the agreement that since the failure was wholly due
> to improper installation that I would pay for the parts and apply for
> warranty reimbursement from the outfit that installed the transmission.  He
> arranged to have the R&R done in Chatsworth as a "favor" from an excellent,
> long time service provider, Scott Tiffany at Bugs and Imports at no cost to
> me.
>
> That's what I call bending over backwards to ensure customer satisfaction.
>
> All in all a ~1600USD bill was reduced to the cost of parts (~300USD).
> Saved me ~1300USD.
>
> Transaxle Engineering was really under no obligation to provide the R&R from
> their own pocket as that is not covered under their warranty.  Conceivably,
> they could have pointed out that the defect was not due to any workmanship
> or materials provided by their company and left me to rebuild the
> transmission on my own.
>
> This quality of service and customer satisfaction, provided by Larry'Z, Bugs
> and Imports, and Transaxle Engineering seems all to rare in today's
> automotive repair environment.
>
> I applied to the outfit that installed the transmission for warranty relief
> in mid December.  They're located in another state and although I have
> repeatedly asked for reimbursement on this and other warranty related items,
> I have yet to see any funds.
>
> YMMV.
>
> pensioner
>