This is the all-too common 091-1 transmission failure of the 3rd/4th gear
hub. I have it documented with pictures at
http://volksweb.relitech.com/091trans.htm

Time for a rebuild, I'm afraid.

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

> -----Original Message-----
> From: Maurizio Penna [SMTP:pennam@HOTMAIL.COM]
> Sent: Friday, October 08, 1999 8:57 AM
> To:   vanagon@GERRY.VANAGON.COM
> Subject:      Blown Transmission?
>
> Hello,
>
> The 4-speed manual transmission in my 86 Vanagon is acting up:
>
> Initially, the gear box was getting stuck into 3rd or 4th, then it started
> grinding while engaging 3rd and 4th gear.
>
> I drained the oil from the transmission and found lots of metal on the
> drain
> plug and in the oil. (The oil had been changed 30,000 km ago)
> I then flushed the tranny with 3 liters of 80W90 and filled it with
> DuraLube
> and synthetic 80W90.
>
> Although the transmission now works very smoothly, there still appears to
> be
> no syncro for 3rd & 4th gear.
>
> When the engine is not running, all gears engage very easily and smoothly
> so
> I don't think it is a shift-linkage adjustment problem.
>
> I checked the clutch hydraulic system and everything appears to be working
> -
> (smooth operation and full clutch release).
>
> Is this a common problem at just under 100,000 km (60,000 mi) ?
>
> If you have any suggestions please cc me on this e-mail account as I am
> unfortunately unable to be part of the list.
>
> Thanks,
>
> M.Penna
>
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