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Thu Apr 12, 2012 11:47 am

So I'll try to keep it short. 69 Fastback. Be gentle, I'm learning to work on cars and do things the right way as I go along with this project.

I got a new shift rod bushing and have gone through the forums searching about the procedure to install it and felt confident enough to get it done.

Here's where I think the problem started. I don't remember what gear the car was in when I had started the project. I think neutral but I'm not sure anymore because I hadn't considered it important. :roll:

I went ahead and uninstalled the shifter then proceeded to uninstall the shift rod through the lower access panel from the coupler and transmission. Removed the bolt that holds the pinch for the coupler, removed the allen key to disconnect it from the trans to turn the coupler so I can get at the pinch and removed that.

So all is well, I removed all the access panels at the front of the car and the shift rod was out. Cleaned, greased and put the shift rod bushing onto the rod and left the bushing at the tapered end of the rod where the rod would go into the coupler. I figured this will allow it to slip into the bracket in the tunnel where the shifter is supposed to be.

Reversed the process, broom in hand I worked the shifter back into the tunnel and with the bushing at the tapered end, installed with the circlip it went into the bracket no problem and the rod was on it's way back towards the coupler with the bushing now aligned and seated.

Here's where the problems started. The transmission is in neutral (?) yet the alignment of the coupler only allows it to be attached so that by the time I get the pinch and bolt back in and align the hole for the allen key for the transmission, the shifter pocket is moved over to the passenger side and when wiggling it as if it were in neutral it brings the shifter pocket straight up and back towards the passenger side of the tunnel. Not an even side to side from driver to passenger side like neutral should be.

So needless to say this 3 hour job turned to 6 when I tried everything I could to get it to align properly. I installed it improperly and made SURE it was in neutral before uninstalling it again at the coupler.

I finally decided to call it a night and installed everything with the shifter misaligned, again. Instead of straight up and down being 1st and 2nd, it's 3rd and 4th. To the FAR left and up is 1st and to the FAR left and down is 2nd. Reverse is no longer accessible and the shifter has no slack to go towards the passenger side when doing a neutral check.

I'm at a complete loss here, I have no idea what else I can try to get it to install properly, I spent about 3 hours just trying different installation procedures, rotating the shift linkage 180 degrees, putting the coupler on the other way, putting the pinch in different ends, unbolting and bolting the transmission allen key end any which way possible. Still no go. It always lines up the same way. No reverse, 1st to the left and up, 2nd to the left and down, 3rd straight up and 4th straight down and no room to go towards the passenger side where 3rd and 4th should be.

I'm currently searching through the forums for any more insight but thought I'd post this for any additional help. Much appreciated.

Thu Apr 12, 2012 1:30 pm

Not mentioned,I think ,did you replace shifter stop plate with the tabs in the right position,short tab on driver's side?

Feel your pain, did mine last month,how ever had no problems with finding the gears.

:)

Thu Apr 12, 2012 1:43 pm

Yep I'm pretty sure it is, smaller tab on drivers side, tabs facing up. From my previous thread I remember that like the back of my hand now.

Here's an idea, is it possible that the bracket underneath the tunnel is bent? The shifter on this car previously had problems going into third and I think the previous owner had done a number on it considering there wasn't a bushing to be found when I removed the linkage. And it had a bug pack short throw so it really took a beating (I think). It's possible now that I've got a new bushing the rod is aligned proper but the actual bracket is bent towards the passenger side... ?

Funny how that works. This car really has a mind of it's own and quite the personality / attitude.

I fix the reverse lights before attempting the bushing, then lose reverse gear! ](*,)

Thu Apr 12, 2012 5:04 pm

Is it a type 3 hockey stick?
I bought an aftermarket hockey stick that was supposed to be Compatible but its not

The correct one is on the left.
So if it is the correct one the linkage will be turned in that direction.

Depending on where you tighten the shifter down you can lose gears and gain them by moving the position of the shifter .

Thu Apr 12, 2012 5:39 pm

No nothing like that. Standard linkage you see on most VWs.

The transmission is a freeway flyer, don't know much about it.

Fri Apr 13, 2012 1:08 am

It is not important in which gear you left before you disassembled the coupler. Due to the blind hole in the hockey stick it will automatically find its only possible original position when alligning with the square grub screw!

Are you sure about the correct hockey stick? In assembled condition you can't tell the difference, as only the blind hole is on a different angle!
(using W1K1's pic again)

From everything you describe, it is highly likely that the hockey stick was a beetle one from the start which caused the diffculties the PO had.
I had the exact same issues, no reverse and stuff like that. Instead of pulling the motor, pulling the trans, change the hockey stick, here is what I did:
http://www.yeti69.blogspot.de/2011/10/look-mum-no-gears.html
good luck!

Fri Apr 13, 2012 6:36 am

Yeti69 wrote:
From everything you describe, it is highly likely that the hockey stick was a beetle one from the start which caused the diffculties the PO had.

That's what it sounds like to me too. It wouldn't be the first time this happened either. A lot of people don't know there's a difference (even the parts sellers), and it will trip you up every time. And since the trans is a "freeway flyer", is a good possibility that it's got the wrong hockey stick in it. :roll:

Fri Apr 13, 2012 10:50 am

:-k EDIT: Ah! Okay I see now. The punch is to the side on the hockey stick. Not in the middle when enganging neutral and doing a neutral check. It should be center... And the coupler is tapped bringing it to the side as well when trying to re-engage it to the hockey stick I think we found the culprit! :x

Thanks Yeti69 for the link. What size tap did you use for the threading? I think I can handle re-tapping the coupler, I believe it's aftermarket so there's room for a 2nd hole. With a few sharpie marks on the coupler I have to synchronize the hole then tap 180 degrees away from the already tapped stock hole.

Appreciate the input gentlemen and for taking the time to read my 10 paragraph "I'll try to keep it short" lol

Fri Apr 13, 2012 2:01 pm

If you drill and tap at 180° you would gain nothing - same shit as before!
I only flipped it 180° before I drilled because the new hole would run into the old hole if you wouldn't flip the coupler!
crappy sketch:

If I remember correct I think it is about 15° to 20° less - or more then 180° - depending from which side you look at it. Maybe the pics in my link will help to roughly locate it correct. Regarding the size I'm not really sure but I think it was a M6 Metric - of course :wink: as the set screw had that thread.

Fri Apr 13, 2012 2:19 pm

Yeti69 wrote: If you drill and tap at 180° you would gain nothing - same shit as before!
I only flipped it 180° before I drilled because the new hole would run into the old hole if you wouldn't flip the coupler!
crappy sketch:

http://images.thesamba.com/vw/gallery/pix/915712.jpg

Yes, I'm sorry my wording makes it sound wrong. The sketch was exactly what I had meant to do. Thanks for the clarification. 180 degrees away from the newly measured hole about 20 degrees way from the old hole.

Thanks for the help.

Mon Apr 16, 2012 10:33 pm

I'd just like to make a follow up post to let you guys know that I have visited the machine shop today and had the coupler re-tapped and we are back in business!

Thanks soooo much to everyone who took the time to help me with this especially the extra effort you guys went through to make sure I understood what the hockey stick was about!

Thanks, MOCHABILL, W1K1, Yeti69 and bobnotch. Much appreciated, mates. Cheers.

Tue Apr 17, 2012 9:51 am

Hey,
good to know everything is working now! That's what this forum is all about!
Keep us posted with your project!