Something just strikes me as "wrong" that I should have to pay the
dealer for a new shift rod just because a little nylon piece has fallen
off.  I mean it's basically just a piece of pipe, nothing at all to
"wear out" otherwise.  So I decided to see if I could fabricate
something.

A small plastic/poly kitchen cutting board from Wal-Mart provided the
source material.  I measured the bare metal finger on the shift rod
fork, and used a jigsaw to cut a small piece out of the cutting board.
Then using a file and sandpaper I shaped the piece, tapering one end,
and also making it a little thinner since the stock cutting board was a
little too thick (comparing to the other side of the fork which still
has it's cover piece intact).  Then using a dremel tool I made a hollow
slot (like a mortise) in the piece so it would fit over the bare metal
fork on the shift rod.

I degreased the metal with brake cleaner, filled the hollow in the
plastic piece with JB Weld, and pressed it into place.  We'll see how it
holds up, but I think it's worth it as an experiment.

Allan
--
1991 Vanagon GL

"Jaime Forero" <jforero@sbcglobal.net> writes:

> You should have a nylon cover on each of the 2 fingers of the fork.  I
> bought the rod from VW about a year ago and replaced it.  Grease up
> the contact area as well as you can.  Adjust and you will be in
> business.
> Cheers
> Jaime
>
> ----- Original Message -----
> From: "Allan Streib" <streib@CS.INDIANA.EDU>
> To: <vanagon@GERRY.VANAGON.COM>
> Sent: Saturday, October 25, 2008 1:47 PM
> Subject: question about 4-speed shift rod front "fork"
>
>
>> Is there supposed to be a plastic or nylon "finger" on each side of the
>> fork on the front of the shift rod?  Looking at the illustration in the
>> Bentley it seems that there is, I only have one on the 3/4 shift gate
>> side, not on the reverse gate side.
>>
>> If I'm missing one, are these available?  Or would I be looking at
>> trying to fabricate something?  Anyone know the dimensions?
>>
>> Allan
>> --
>> 1991 Vanagon GL
>

--
1991 Vanagon GL