On Thu, May 20, 2010 at 8:27 PM, Jim Johnston <inmytree1@gmail.com> wrote:
> I had to replace the shifter ball on my 4-speed manual transmission in my
> 1991 GL. �Now I can't get into reverse. �I push down and over, and it goes
> into first. �I'm following the Bentley procedure to align the shifter. �I am
> missing a plastic tab on the front shift rod, but didn't think that would be
> that big of an issue. �Anyone else run into this? �Any ideas or guidance?
>
> I have to say, trying to get the shifter lined up has been one of the most
> frustrating jobs I've done on my Vanagon.

Double check, but IIRC Bentley specifies 23 mm between side of shift
lever (fork) and rail in housing, when transmission and shift lever in
neutral. They suggest cutting a strip of metal to use as a guide.

I'm a one man show, so as an experiment, tried this (pic):

http://tinyurl.com/38pw7zb  You can just see the plastic on the fork.
If missing, I guess one could adjust the linkage to that, but then it
would scrape on the rail. And FWIW, that fork ends up under that rail
on pass. side of box when transmission in reverse. If that plastic
missing, not sure how it would affect shifting into reverse.

IIRC, I ended up putting a vicegrip on front rod, moved it a spline or
2 either way, then checking with metal strip in hand. AFAIK, the idea
is to adjust the front shift rod to the "stationary" position of rear
since the spring in transmission determine where the shift lever in
cab should sit when transmission in neutral.

On my linkage, noticed some play at U joint at rear shift rod. It
occurred to me that if play was excessive, it might make adjustment at
front and rear rods meet (splined bit) a bit more challenging. Just a
thought.

If old ball/socket was really worn, maybe linkage was adjusted to
compensate for that, so new parts have changed the alignment somewhat?

Neil.

-- 
Neil Nicholson '81 VanaJetta 2.0 "Jaco"

http://tubaneil.googlepages.com/

http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines