First, let me thank all who have offered advice to date. I appreciate your
time and patience with my problems. I feel so frustrated, having a
wonderful Westy, with 2 kids just rarin to go camping, and I can't drive
this thing more than a few miles without the clutch problem kicking in...

Recap:

Clutch refuses to disengage when shifting. Seems to happen somewhat
intermitantly, but almost guaranteed to happen at least once during any
driving outing. Great example: Spent 8 hours today, changing all gear oil,
engine oil, and other maintenance tasks. Checked master and slave cylinders
by bleeding line oil (opened slave nipple with clutch pedal depressed..
repeated twice). Took the van out for a spin, shifted like butter. Drove 10
miles or so cycling from 1st through 3rd primarily. Came back on a big
road, hit it into fourth.. still no problem.. came to a turn and went to
downshift into third, and no clutch release.. had to coast to a stop,
jiggle shift lever, pump clutch, etc..kicked back into gear. Went a few
more miles, in third, downshift to 2nd for turn, happens again. Then clean
sailing all the way back home 2nd & 3rd gear. I seem to be hitting a
pattern.. everytime I pop into fourth and then downshift problem occurs...
maybe a pattern..I'm so damned tired and confused....

Suspects:

Master/Slave - I did the line test. When the clutch was depressed, a
healthy stream of fluid came out. Repeated twice, same result. Could air
still be getting into the system somehow? Any other tests I should perform?
No leaking fluid anywhere that I can see...

Shifter linkages - I didn't pull the spare out and check the front
bushings, etc. I don't seem to be having a problem with the shifter
selecting the wrong gear.. revcerse, granny, 1st, 2nd third etc. all seem
to be in the right spot. Rear bushings, etc. don't seem to be a problem.
I'd love to find out that this, and not my clutch/tranny is my problem but
given my experiences so far, I don't believe this is the case... but maybe.

Transmission - the final frontier - Something is wrong with the gears,
clutch, etc. I have no experience at all w/ VW transmissions, so I can't
begin to speculate about likely causes. My worst fear is having to drop the
transmission to fix clutch or tranny parts (both from a time and materials
cost perspective), but I fear this may be inevitable. Any and all
speculation and remedies sincerely appreciated.

On a postive note, the engine is running strong and the front syncro
differential is in great shape. It would be a shame to toss in the towel on
such a fine vehicle, but I fear I'm getting close to the edge of my
mechanical abilities (not so much knowledge or desire.. I've worked on cars
and motorcycles for years in my younger days.. I just don't have the garage
space and many of the tools needed to do intense work like tranny removals
& rebuilds).

Again, thanks to all who have waded through my saga before, and again this
time. I sincerely appreciate the help I have gotten, and without this list
I would have been sunk by now.

Syncronauts..your help is needed!!

Bill
87 Westy Syncro
Princeton NJ area

"Once in a while you get shown the light in the strangest of places if you
look at it right"

Hunter/Garcia