Reply to:   Re: Shifter Rattle (Was: Re: shift lever adjustment)
Mark,
I was having this same rattling noise above 65mph which I could ease by pushing the  gearshift lever to one side or the other.  My shift pattern has always been a little strange and indistinct so today I lifted the boot and made a tiny (1/4" or less) adjustment on the plate  and lo and behold....the rattle doesn't appear below 70 mph.  I haven't had it any faster than that yet but its definitely improved it and my shift pattern is more distinct.
My 2� worth
Jim in Iowa
91 Passat Wagon GL
89 Westy
66 Beetle

Mark Drillock wrote:
>Wes, if you look on page 34.6 of the latest Bently, drawing #34-1297,
>you can see a part labeled 'shift rod, front'. The front end of this has
>2 square tabs or ears that stick up above where a long bolt goes
>through. This square ears are supposed to be covered with thick clear
>vinyl. This is the plastic that wears away and falls off, allowing metal
>to metal contact.  The replaceable guide part is not really visible in
>this drawing but it is labeled 'shift stop' and is found inside the
>'shift mechanism-housing', held on to it by 2 bolts that are visible. I
>bought a new front shift rod and shift stop for around $75 from the VW
>dealer last year.
>
>Wes Neuenschwander wrote:
>>
>> Mark,
>>
>> It sounds like you may have absolutely drilled it.  I must confess that I
>> have very little *first hand* knowledge of the shift box stuff, having
>> left the problem pretty much to the VW shop mechanic (the local VW dealer
>> was very good about treating this as a warranty problem) and also due to
>> the fact that I don't have any ramps or other convenient way to get at the
>> front linkage area.
>>
>> I think I'll run the van down to my favorite local indie shop next week
>> and see if I can get them to install new guides.
>>
>> BTW, Mark, is there any place where these components are illustrated?
>> I've gone through Bentley (very little detail) and the few times I've
>> actually mucked about in the shifter linkage there was so much dirty old
>> grease I couldn't really see what was there.  I even have a set of old VW
>> microfiche parts lists that I could check out (if I had a clue where to
>> begin looking, I guess).
>>
>> BTW #2 - perhaps you could post this reply to the list as well?  I really
>> think this information is important to anyone who has the rattling shifter
>> problem (or as Coby Smolens put it in another private email reply to me on
>> this subject, the "Klapperschlange-in-the-shifter" problem).
>>
>> Thanks, again, Mark.  Great info.
>>
>> -Wes
>>
>> > Date:          Fri, 16 Jul 1999 20:54:18 -0700 From:          Mark
>> > Drillock <drillock@earthlink.net> Reply-to:      drillock@earthlink.net
>> > To:            Wes Neuenschwander <wesn@ESKIMO.COM> Subject:       Re:
>> > Shifter Rattle (Was:  Re: shift lever adjustment)
>>
>> > I think that the cause of the sound may be the plastic covered guides at
>> > the front of the shift rod. The plastic wears off gradually until it
>> > falls off entirely. Then there is metal to metal contact when the lever
>> > is to one side or the other. The metal plates that these contact are
>> > replaceable also (at least one is). Drop the box down and look for
>> > yourself. The "ears" are supposed to be completely covered by a clear
>> > plastic coating. Grease in this area might quiet the noise for a while.
>> > The worn parts and missing plastic ears gives the shift lever more room
>> > to rattle in.
>> >
>> > Mark
>> >
>> > Wes Neuenschwander wrote:
>> > >
>> > > Excessive play in the shift linkage and bushings was carefully considered
>> > > ruled out in both the '82 and '91 (actually replaced the front bushing in
>> > > the '91, but no improvement).  Front and rear linkages have been relubed
>> > > (sometimes a temporary improvement), as have the bushings.  And at least
>> > > in my case(s) the noise does go away when I push the stick away from the
>> > > sides of the gate box.  Ditto if I push the shifter towards the gate.
>> > >
>> > > I think it's also interesting that (at least in my case) the problem goes
>> > > away if I either accelerate or decelerate, which -among other things -
>> > > does torque the shifter linkage slightly, emulating, perhaps, the effect
>> > > of manually pushing the shifter knuckle away/towards the gate.
>> > >
>> > > However having followed this issue here for a few years now, I think its
>> > > likely we may be dealing with multiple causes (alas, vanagon life is never
>> > > simple).  Others have previously suggested worn engine mounts, excessive
>> > > engine vibration, transmission problems, in addition to the worn shifter
>> > > u-joints, bushings that Randy has pointed out as possible causes.
>> > >
>> > > I think in all cases though its important to focus on where the noise
>> > > itself originates.  A fair amount of mechanical vibration can be
>> > > tolerated without causing audible noise.  It's where the mechanical
>> > > energy is converted into sound energy that the noise occurs.  At least in
>> > > my particular case this noise is clearly coming from the shifter
>> > > assembly.  I suspect that even with minimal mechanical vibration, a
>> > > substantial amount of noise can be created by the effect of the shifter
>> > > knuckle vibrating against the gate, which then transmits the sound energy
>> > > through the enclosure (below the floor) and floor pan, in addition to
>> > > direct transmission through the shifter itself.
>> > >
>> > > -Wes
>>
>> Wes Neuenschwander
>> Seattle, WA
>> wesn@eskimo.com
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