Just replaced all shift boots and seal. Now shift issues...

Rjhdog

I just replaced all the boots on the shift linkage next to side of tranny. I also replaced selector shaft seal as well but removing the reverse housing on other side of tranny.
Re greased all bushings etc.
Reinstalled everything and now I am having a very difficult time getting it to shift properly. The shift ball is coming half way out of the cup when shifting into 2nd or fourth as well as reverse and then jams up as the ball hits the edge of the cup. The shift rod has too much movement forward.
I tried adjusting shift plate in cabin but to no avail.

Please help!

Is it possible that the shift ball level can be reinstalled incorrectly. I think there is only one way for the teeth to align, right?
It's almost like the ball isn't far enough down in the cup but I may be incorrect.

I did try hammering out the roll pin and may by some chance bent the linkage rod but I hope that's not the case.

Any thoughts here.
Thanks!

vanonimous · Posted: Mon Mar 31, 2014 8:51 pm Post subject:

Possibly misindexed shift arm on shift shaft? It is supposed to be horizontal in neutral.
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Rjhdog · Posted: Mon Mar 31, 2014 9:16 pm Post subject:

PDX_Greg · Posted: Mon Mar 31, 2014 9:28 pm Post subject:

Did you adjust the linkage in the gear box (from under the van)? Bentley shows you how and provides the correct measurement for adjustment. The shift plate is only for minor adjustments.
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vanonimous · Posted: Mon Mar 31, 2014 9:31 pm Post subject:

Just looked at a spare I have and it can not be misindexed. There is a spline missing from the factory preventing that scenario.
I just rebuild both my van's shifters and they shift beautiful. I did it without separating the shift rod, did you separate yours?
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davideric9 · Posted: Mon Mar 31, 2014 10:10 pm Post subject:

Check the bracket that holds the shift rod to the transmission forward of the ball. You may have it on the wrong side of the mounting point. This can be connected either forward of aft of the attachment point. I'll check in the morning, maybe with photo.
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1987 Syncro Westfalia, stock (bought 1994)
1986 Syncro Westfalia SVX, 3 knob (bought 2008)
1987 Westfalia (bought 2010)
1988 Wolfsburg GL (bought 2012)

Rjhdog · Posted: Mon Mar 31, 2014 10:11 pm Post subject:

If I understand this correctly:

I did separate the shift rod in order to hammer out the roll pin to remove the cup in order to replace the boots. If that's the shift rod you are asking about.

It was just a circlip and pin at the knuckle midway up to remove the rod if I am talking the same thing?

It's good to know that its impossible to misindex...

So is adjusting in the box my issue?
I didn't mess with that at all so I don't understand why i would need to readjust that?

Rjhdog · Posted: Mon Mar 31, 2014 10:17 pm Post subject:

[quote="davideric9"]Check the bracket that holds the shift rod to the transmission forward of the ball. You may have it on the wrong side of the mounting point. This can be connected either forward of aft of the attachment point. I'll check in the morning, maybe with photo.[

I have the mounting plate attached forward to the front of the van. I could see how the mounting plate could get attached on the other side towards the rear. Is attached towards the front correct?

goffoz · Samba Member Joined: May 09, 2007 Posts: 1486

try here,,the search is your friend
http://www.thesamba.com/vw/forum/viewtopic.php?p=6281511&highlight=#6281511

Rjhdog · Posted: Mon Mar 31, 2014 10:37 pm Post subject:

I mounted plate on the ears so plate is closest to front of van. Is that right?

levi · Last edited by levi on Mon Mar 31, 2014 10:40 pm; edited 1 time in total

...
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Rjhdog · Posted: Mon Mar 31, 2014 10:37 pm Post subject:

Notice how ball comes out of cup and jams up.

Any thing look incorrect in terms of mounting placement?

Thanks all

Image may have been reduced in size. Click image to view fullscreen.

levi · Posted: Mon Mar 31, 2014 10:43 pm Post subject:

Rjhdog · Posted: Mon Mar 31, 2014 11:17 pm Post subject:

MarkWard · Posted: Tue Apr 01, 2014 6:52 am Post subject:

Did you replace the ball? It looks like it is just too short, but there is no adjustment for how deep the ball is in the cup. If you did replace it, compare it to the old one. From the factory, there is a special nut and washer that sometimes gets lost. The bracket is then not secure against the shift rod splines. If you only have the nut, it will not tighten down correctly, because it hits the splines.
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Rjhdog · Posted: Tue Apr 01, 2014 7:56 am Post subject:

Same parts. Same ball and cup. Only thing new are boots and seal.

I think that I misindexed the ball part at the splines. Is it possible to install off angle although it looks like the slots for the splines look to go on only one way? As there are two flat spots on part?

wecm31 · Posted: Tue Apr 01, 2014 8:13 am Post subject:

goffoz · Samba Member Joined: May 09, 2007 Posts: 1486

From what I can see in your pics, maybe, when you reassembled the yoke, you shortened the linkage slightly.
check just forward of the yoke, there is a clamp joint where the shift rods slide into each other, they can be shortened and also be rotated here.
If your clamp is loose, it could have slipped in a bit shortening the whole thing.
This would explain why your cup is travelling to far forward.

I assume you pulled the rubber boot for the pic, but in case you don't already know , that boot on the cup can seat all the way down.
There is a grove in the plastic, above the ball that the boot snaps into, then the lower skirt can slip over the cup and will stay there.
Its awkward to do Rolling Eyes

MarkWard · Posted: Tue Apr 01, 2014 9:53 am Post subject:

With the van in neutral, with the shift rod disconnected, it should point straight down. From memory, the shift shaft is missing one tooth and the ball piece should only fit in one spot, but like I mentioned earlier, if it was misinstalled and running loose, it could be completely hammered. I'd be inclined to replace the ball piece anyhow as part of this repair. It does wear.
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davideric9 · Posted: Tue Apr 01, 2014 9:58 am Post subject:

I had the exact same problem when I took things apart in this area (and not the joint in the shaft). I wish I could remember howI fixed this, but I do know I had something assembled wrong, maybe the shift lever (ball piece) was not seated correctly. Double check the assembly before you replace anything.
_________________
1987 Syncro Westfalia, stock (bought 1994)
1986 Syncro Westfalia SVX, 3 knob (bought 2008)
1987 Westfalia (bought 2010)
1988 Wolfsburg GL (bought 2012)


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