I installed new shift rod bushings (center, just behind the gas tank,
and rear, at the transmission) as well as a "repair kit" for the linkage
bits at the transmission end.  I now effectively have all new shift
linkage and bushings from front to back, since I installed a repair kit
for the shifter itself a few months ago.  The only thing I have not
replaced is the universal joint in the middle of the van.

I tried to adjust the shifter according to the Bentley procedure.  It
calls for a 23mm gap between the reverse "fork" and the reverse lockout,
which I tried but as before found it completely incorrect.  I was not
be able to get into reverse with that adjustment, and had first gear
where reverse should be.

So, I had to twist the slip joint in the center of the van.  I found
that I had to have the shifter against the reverse lockout and then
twist the rear linkage counter-clockwise about one more notch.  That got
me close, and then I fine-tuned by adusting the base plate on the
shifter in the cab.

I have not yet taken it on the road, but am hopeful that I'll have a
good gearshift feel after all this work.  It feels pretty good just
standing still, but the true test will be driving it.  I need to button
up some electrical work on the dash (trying to replace the lamps that
illuminate the heat/vent controls) and then I'll take 'er for a spin.

Allan
--
1991 Vanagon GL

Allan Streib <streib@cs.indiana.edu> writes:

> Someone asked for pictures -- I did not actually take any as I went
> along, but here's a shot of the finished product.
>
> http://picasaweb.google.com/allanstreib/Shifter#5262242323547866834
>
> Haven't actually tried it out yet -- new shift rod bushings arrived
> yesterday and I'll be installing them this afternoon.
>
> Allan
> --
> 1991 Vanagon GL
>
> Allan Streib <streib@cs.indiana.edu> writes:
>
>> 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
>>
>
> --
> 1991 Vanagon GL
>

--
1991 Vanagon GL