I think your shop is screwing something up.  If the hydraulics are good, this can happen with a bad or crushed pilot bearing, my guess on what's causing this.

Much less likely is a warped (factory defect) pressure plate, but that actually happened to me once. 

Someone is going to have to pull the tranny again and look for these things, and likely replace the entire clutch along with the pilot bearing. 

Good luck!

Stuart

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of David Boan
Sent: Monday, December 29, 2014 5:12 AM
To: vanagon@GERRY.VANAGON.COM
Subject: Rebuilt transaxle grinds

I have an '85 Westy and six months ago put in a GoWesty engine and got a rebuilt transaxle from German Transaxle at the same time.  My local shop installed both, and put in a new clutch and cooling system.  Second gear would grind and shift hard into second, so pulled the Trans and sent back to German Transaxle.  They replaced second and the syncro, but also said they were fine and the problem likely in the clutch or linkage.  Shop says the clutch and linkage are fine and say the problem is with the transaxle.  The problem continues and shop says they are done trying to fix it.  Very frustrating being in the middle.  

I am looking for a shop in the Chicago area that can look at the Trans and welcome any suggestions or any advice about the problem. 

Thanks
Dave
Wheaton, IL