Daryl,
    Thanks for the info., I've updated a few of the shift linkage
on 1986 syncros, with the rubber boots.  For the life of me I could
not figure out what the washers where for.....thanks again

            Eric                   86-VW4x4
            vw4x4@fyi.net          86-SS Syncro
            Pittsburgh, PA USA     1936-Chrysler
                                   92-Jetta GWC
            www.fyi.net/~vw4x4/vw4x4.htm

On Sun, 13 Jun 2004, Daryl Christensen wrote:

> Al, et all...The later tranny gear carrier housings were updated around 88
> by VW with wider bosses where the linkage plate bolts to the trans so the
> linkage rod wouldn't bottom out and keep it from fully engaging 2nd or 4th.
> There was a tech bulletin I was told that says put a pair of 6mm washers
> between the plate and the housing bosses to give some more room for the
> "float" of the shift rod. The only ones I have seen with the problem are
> ones with the rubber accordian boots still intact. The rubber gets
> compressed adn tries to push it back out of gear.
>  Kinda confusing I know until you look underneath at the setup to see what I
> mean...Hope that helps someone.
> Daryl of AA Transaxle
> Duvall, WA. (Seattle area)
> 1-877-377-0773 toll free
> 425-788-4070
> aatransaxle.com
>
>
> > Anyway inquire of a good rebuilder how to determine this float.  The
> > defect
> > occurs when the plate
> > to which mark refers pushes against the shift rod slightly enough to
> > partially disengage the gear under load.
>
>
>
>
> ----- Original Message -----
> From: "Al Knoll" <al_knoll@PACBELL.NET>
> To: <vanagon@GERRY.VANAGON.COM>
> Sent: Saturday, June 12, 2004 10:14 PM
> Subject: Re: Syncro tranny problem
>
>
> > Mark said:
> >
> > Date:    Fri, 11 Jun 2004 18:46:51 -0700
> > From:    mark drillock <drillock@EARTHLINK.NET>
> > Subject: Re: Syncro tranny problem
> >
> > This is a very common error. You likely attached the linkage wrong at
> > the tranny. The plate that bolts to the ears on the tranny can be bolted
> > to the wrong side of the ears quite easily. When you do it wrong there
> > is not enough travel available to bet all of the gears to engage. With
> > the shifter in neutral, look at the rub/wear area on the shift rod at
> > the tranny bushing. You should see an equal amount of wear/rubbing marks
> > on both side of the bushing. If not, take the 2 bolts out and move the
> > plate to the other side of the ears.
> > ~~~
> > I will add one more note to the wisdom above.  Make sure that there is
> > enough "float" in
> > the shift linkage.  As the van accelerates and decelerates the
> > transmission
> > moves forward
> > and aft.  If there is insufficient float, second and fourth gears can run
> > only partially engaged
> > and will wear out very quickly.  A transmission R&R done at a shop not to
> > be
> > named forgot to
> > check this all important item on a transmission that I had just had
> > rebuilt.
> > Fourth gear failed
> > after 1600 miles and began to "pop" out of gear under acceleration.  Cost
> > me
> > another rebuild and
> > the shop refused any help in the matter claiming the shift linkage is "not
> > adjustable".  Not so
> > of course.
> >
> > Anyway inquire of a good rebuilder how to determine this float.  The
> > defect
> > occurs when the plate
> > to which mark refers pushes against the shift rod slightly enough to
> > partially disengage the gear under load.
> >
> > I highly recommend as I have done in the past, Jeff Field at Transaxle
> > Engineering in Chatsworth for
> > consultation and repair.  He did both rebuilds for me and the second one
> > is
> > doing just fine after
> > a bazillion miles with a properly adjusted linkage.
> >
>