I hate to say it, but that sounds like a classic example of the 3rd/4th hub
breaking. I have that problem documented at:

http://volksweb.relitech.com/091trans.htm

Unfortunately, fixing the problem requires complete trans teardown and
re-assembly.

TomC
tcarrington@relitech.com
http://volksweb.relitech.com
85 Vanagon Crew Cab
82 Westy diesel=>gas conversion
65 Notchback

> Hi Folks, I think I have a problem.
>
> Patient: 83.5 Vanagon. 145k miles, 20 k miles on a rebuilt motor.
> Symptoms: Very difficult -- just shy of impossible -- to get into 3rd and
> fourth gear.
>
> Treatment thus far: I assumed I had a linkage problem, so I replace some
> bushing and assorted pins (at tranny end) and re-adjusted. Got first,
> second, and third working like butter (at least by hand when under the
> van).
> Couldn't get it into fourth at all. Road tested. Could no longer get it
> into
> third, but first and second (and reverse still fine). Found I could
> "force"
> (as in slam) the lever into 3rd and fourth(!), but then it didn't want to
> come out so well.
>