'83 Vanagon 2.0 Manual 1st gear popping out of gear - SOLVED

[fishgo]

I just added some new parts to the shift linkage on my '83 2.0AC 4 speed. The bushing above the fuel tank was gone, so when I dropped the tank to redo the fuel lines I added that bushing. I also replaced the rear shift linkage hard parts that connect to the transmission (the L bracket with the 2 plastic balls, and the bolt/plastic washer/boot).

The shifter mount plate on the floor up front never properly aligned to the witness holes. I've always been able to fiddle with loosening those two screws and moving the plate slightly when the shifting was poor. Knowing I was redoing the shift linkage, this was the time to get the mount plate properly adjusted first to the two witness holes and then adjust the shift rod itself (where the two rods join -- one with splines, the other with the clamp) to set the shifter properly per Bently and other threads here.

The problem I know have is 1st gear is a bit of a problem, where the shifter won't fully engage (and may pop out of gear when I start from a dead stop) or won't fully get into gear and won't mesh unless I press into 1st with a bit more force on the shifter. This problem doesn't happen every time, but occasionally.

I can fiddle again with the floor mounting plate to get it "close", but am wondering if the two shift rods may be jammed too far together (front with splines, back with clamp). Is it possible now that there are fresh parts and some of the slop is taken out of the shifting that those two rods need to be pulled apart a bit? I saw pictures of another shifter adjustment question where the rods were much further apart than mine.

Could pulling the front and back shift linkage rods a bit further apart solve the first gear (not engaging fully / popping out of gear) problem?

[MarkWard]

[fishgo]

[MarkWard]

How does 3rd feel? Takes about the same movement as 1st. You could disconnect the shift rod from the trans. Manually select first at the transmission and see if it remains in first driving around the block.

[fishgo]

[AndyBees]

Is the shifter lever on the transmission straight up and down when the transmission is in Neutral? That shifter lever has splines that allows it to be installed only one way. But, I have seen them on wrong which affects linkage adjustment.

So, if the shifter lever is not straight up & down when the transmission is in neutral, you need to correct it.

Then, adjust the shifter linkage at the clamp and the in floor shifter as necessary.

That linkage is very easy to work with. My center bushing is a home made custom piece that I did over 12 years ago. My Van is an 84 but has the DK Air-cool transmission. I installed it as part of my TDI engine conversion. So, I had to convert the shifting rods to those for a DK Transmission.

Observe the photos below to see the home made custom center bushing. That's how it looked September, 2024 after 12 years and 90k miles.

_________________
'84 Vanagon Tin-top, ALH TDI, two trips to Alaska, 2014 & 16. 1989 Tin-top unmolested.
1983 Air-cool, 225k miles, 180k miles mine, seven trips to Alaska from 1986 thru 2003. 1975 Bay hopeful.

[fishgo]

Returning to shifter adjustment. Per previous questions:

Rear relay lever (L bracket with 2 balls that attaches to the transmission): is mounted correctly, mounted vertically. Van shifts with fine when not connected to the lever and does not pop out of 1st gear for testing.

Photo above shows the tabs and shift mechanism housing. This van is an '83 AC so there is no driver's side gate, just the reverse lockout on the passenger side right. Per Bently, the adjustment should be 3/4" to 7/8" gap from R lockout to the passenger-side tab.

I'm going to stick my head back under and re-align shifter plate witness holes and then readjust the shift rod. Seems like both the rear linkage is vertical and front shift rod is sitting centered (Front to back) in the housing.

Fingers crossed for proper shifting w/o 1st gear popping out.

[Ggiomett]

Given the refreshed linkage and reduced slop, misalignment in rod spacing can absolutely limit full gear engagement. I’d start by loosening the rear clamp, pulling the rods apart slightly, and rechecking 1st gear feel before road testing.

[AndyBees]

[fishgo]

[fishgo]

Update 6/19:

I think I've figured it out.

After adjusting the rod spacing numerous times (in, out), adjusting the shift rod per Bently, adjusting the shift rod per Samba, adjusting with the shifter bungee-corded to the door...etc. still had the problem of not always finding 1st gear. The mystery got closer to solving when 3rd gear started being a problem as well.

What I found was, when adding the new shift linkage parts to the end of the rod at the transmission, the L bracket, the bolt, the new rubber boot (the old boot was loooong gone), I had zip tied the boot too far rearwards about 1/16" or 1/8" of an inch, causing the shift linkage to not always go as far back as it needed without forcing it or compressing the new boot too much. I snipped the zip tie, moved the boot forward slightly, re-adjusted the shift rod, aaaaand now 1st & 3rd are happy.

Looking closely at the front, at the base of the shifter and all those plastic parts reveals some wear here as well which will need future attention.

But I'm just going to put some miles an camping and visiting for a bit and return to this later.

Good suggestions all. I HOPE this is it. And I've gotten really good at shifter adjustment.

[dobryan]

_________________
Dave O
'87 Westy w/ 2010 Subaru EJ25 (Vanaru) and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

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