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youremyboyblue Samba Member
Joined: December 01, 2009 Posts: 38 Location: whereever my tdi syncro will take me!
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Posted: Tue Dec 08, 2009 12:42 pm Post subject: Shifter rebuild - how-to (1986 Syncro Vanagon) |
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this is an attempt to document as thoroughly as possible the process. any and all feedback is appreciated! i'll revise the post and post pics as necessary.
here's my dry run from reading the bentley:
shifter rebuild
gowesty parts: Shifter Kit [Vanagon] (VANO SHIFTER FIX 83-91)
Gear Shifter Repair Kit [Vanagon] (251-798-116A)
start of applicable bentley sections 34.10/34.20
general order of install:
phase 1) gearshifter lever bearing replacement (front)
phase 2) gearshifter lever replacement (rear)
phase 3) gearshifter lever adjustment
detailed install steps:
1) gearshifter lever bearing replacement (front)
- open bentley to section 34.10/34.20
- familiarize one's self with gearshift linkage and all components
- set aside tools required
- list
- torque wrench
- socket wrench
- ramps
- chocks/blocks
- gloves
- grease MoS2(?)
- set aside new components to install - insure all parts accounted for
- list
- spacer ring
- rubber guide
- shells
- lower ball half
- spring
- upper ball half
- gearshift lever bearing housing
- washer
- nut
- washer
- nut
- spring
- bushing
- headless screw
- threadless bolt
- black plastic bushings (a & b)
- nut
- review bentley again (and, again)
- assemble gearshift lever bearing (per bentley)
- place shells in rubber guide
1 shell - top:
1 shell - bottom:
both shells - top:
both shells - bottom:
- push lower ball half into shells (collar face up)
lower ball collar upward prior to seating:
lower ball seated in shells:
- insert spring
spring onto lower ball:
- push upper ball half into shells (spring in between)
spring in between bottom lower and upper ball:
spring loaded ball in shells:
- apply moly grease to ball
- push spacer ring into rubber guide from below
- push rubber guide and spacer ring into gearshift lever bearing housing
- screw headless screw into bushing
- prep vehicle for work
- place van on ramps
- ebrake on
- blocks behind wheels
- out of gear (?)
- remove spare wheel (19mm)
- from above, remove shift knob (counter clockwise)
a few twists to the left:
put knob somewhere for safe keeping:
- from below, remove shift mechanism housing - (4) 10mm
a couple shots inside the housing (rear to front):
two of four 10mm nuts of shift mechanism housing:
- from below, remove gearshift lever base from front shift rod front head
gearshift lever to front shift rod connection:
"threadless" bolt, nut removed:
gearshift lever free from front shift rod:
gearshift lever base (upper) and front shift rod front head (lower):
front shift rod front head:
- remove boot
before:
after:
- remove gearshifter lever bearing housing assembly
gearshifter lever bearing housing assembly connections (2) 10mm:
ready for removal:
remove shift lever/gearshift lever bearing housing from van:
- replace with replacement gearshifter lever bearing housing assembly
- reassemble boot
- reassemble knob
- phase 1 complete
Last edited by youremyboyblue on Tue Dec 08, 2009 10:49 pm; edited 7 times in total |
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MarkWard Samba Member
Joined: February 09, 2005 Posts: 17153 Location: Retired South Florida
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Posted: Tue Dec 08, 2009 1:13 pm Post subject: |
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I believe that is the same as CV grease. _________________ ☮️ |
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CessnaJon Samba Member
Joined: August 15, 2008 Posts: 677 Location: Senoia,GA
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Posted: Tue Dec 08, 2009 1:14 pm Post subject: |
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Just redid my shifter front to back on my 90 Westy.Part Geek has the shifter repair kit for $96 - original VW(base of shifter). Front and rear bushings, boots (3 total) and cup w/ relay lever from Go Westy.Short shift kit was from Van Cafe.I left the universal joint alone- was not worn.While you have it apart, check the front shift rod ears that guide it through the gate and the base of the shifter.Mine were long gone-fixed it with some 5 minute epoxy- smooth as owl poop now! _________________ 1973 Westy (shared birthday)
1990 Westy Multivan
2015 Passat TDI 6sp
2015 Sportwagon TDI 6sp
LR-JET, Gulfstream 159 |
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youremyboyblue Samba Member
Joined: December 01, 2009 Posts: 38 Location: whereever my tdi syncro will take me!
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Posted: Tue Dec 08, 2009 11:35 pm Post subject: upon further inspection ... |
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the good news (for now) is, the plastic dog ears look to be intact!
additionally, from what i can see, the existing gearshift lever/bearing/housing is in good working order. there's just a bit of upward play, similar to that of the newly assembled bearing. aside from the black grease, there is a redish/orange grease also. lastly, without opening the bearing, all plastic bushings look to be whole and no cracks.
i wonder if this has been replaced already or just held up this well after 20+ years. the bearing housing is the "old" style.
existing gearshift lever/bearing/housing:
black grease & "solid" plastic bushings:
redish/orange grease:
unless anyone suggests otherwise, i think i'll just clean everything up, put things back together and move on to the shift rod lever in the rear. |
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wyomingresident Samba Member
Joined: April 22, 2007 Posts: 246 Location: Jackson Hole
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Posted: Thu Oct 13, 2011 8:54 am Post subject: |
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Bump for awesome post!
Relevant info too! _________________ Don't tell fish stories where the people know you; but particularly, don't tell them where they know the fish.
Mark Twain |
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debbiej Samba Member
Joined: December 14, 2008 Posts: 1556 Location: las cruces, nm
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Posted: Wed Feb 29, 2012 5:19 pm Post subject: strong hands, tecnique or tools? |
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very helpful |
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rfoubi Samba Member
Joined: March 21, 2004 Posts: 224 Location: Rossland BC
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Posted: Mon Mar 12, 2012 10:41 pm Post subject: |
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nice, im doing the same right now. The only thing that would more helpful is if your photos were a little darker and blurrier. thanks |
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Chris Vellat Samba Member
Joined: April 09, 2004 Posts: 1590 Location: Seattle, WA
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Posted: Mon Mar 12, 2012 10:54 pm Post subject: |
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rsxsr wrote: |
I believe that is the same as CV grease. |
Correct, it's called molybdenum disulfide grease. _________________ (3) '69's
'67 Baja
'74 Super
'73 Bay
(2) '77's |
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rfoubi Samba Member
Joined: March 21, 2004 Posts: 224 Location: Rossland BC
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Posted: Mon Mar 12, 2012 10:57 pm Post subject: |
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on a more serious note, is there an easy way to align the bolts before tightening? I cant get seem to get the shifting back to smooth normal after reinstalling. It makes sense when i go under the van and manually move the linkage, but when it comes time to bolt it on from the top, i either cant hit neutral, or have 1-4 but cant pop into reverse, etc. |
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Darren2dream Samba Member
Joined: April 12, 2011 Posts: 162 Location: Redwood City, CA
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Posted: Sat Jul 21, 2012 7:06 pm Post subject: |
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*bump*
I did this job today and am having the same problem as the last post had but it looks like no one had any suggestions at that time.
The van seemed to shift ok when up on the jacks, I took it down, cleaned up, tried it out and what I thought was reverse seems to be first & I have no reverse... Tomorrow I want to lift the van again & mess around with various bolts to play with the alignment but I'm not sure where I should start.... any suggestions?
I will say that even though it dosen't shift in the right pattern, it's an amazing improvement from what I had.. My plastic ball joint disintegrated last weekend.
*EDIT* Thanks to other fantastic posts here I was able to gain some amazingly valuable insight & align the shifter just fine... NOW to do the back end, a bit that seems easier since it's just one screw but, I'm totally afraid of messing things up... _________________ 84' Wolfsburg Westy GL 1.9 Manual |
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0to60in6min Samba Member
Joined: November 27, 2006 Posts: 3416 Location: OR & CA (Oregon/California)
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Posted: Thu May 07, 2015 1:29 pm Post subject: |
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thanks for this post...
I doing it now...
is there any tip on how to get both shells into the rubber guide..? I got itthen in but it take a lot of force and swearing... |
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imdbui Samba Member
Joined: June 03, 2014 Posts: 87 Location: Aloha, OR
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Posted: Fri Jun 26, 2015 9:12 am Post subject: |
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0to60in6min wrote: |
thanks for this post...
I doing it now...
is there any tip on how to get both shells into the rubber guide..? I got itthen in but it take a lot of force and swearing... |
You've probably figured it out by now. But I just put both halves into the rubber guide first, and then realign them to form a circle once they are already in. Then pop the ball in. _________________ 1986 Syncro Westy
1989 tintop Wolfsburg "White Star" |
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0to60in6min Samba Member
Joined: November 27, 2006 Posts: 3416 Location: OR & CA (Oregon/California)
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Posted: Fri Jun 26, 2015 11:40 am Post subject: |
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thanks for tip...
I will use it for my other van... |
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iheartstrangers Samba Member
Joined: May 19, 2010 Posts: 47 Location: Portland, Maine
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Posted: Sat Aug 13, 2016 3:55 pm Post subject: Re: Shifter rebuild - how-to (1986 Syncro Vanagon) |
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Can anyone tell me what function the spring that is held tight by the bushing with the set screw serves?
I am reinstalling all of this as my gear shifter broke, but am struggling to make sense of that part.
Thanks! _________________ --
My name is Joshua and I am just getting started with an '84 Adventurewagen |
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davideric9 Samba Member
Joined: January 21, 2009 Posts: 1001 Location: Oakland CA
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Posted: Sat Aug 13, 2016 5:28 pm Post subject: Re: Shifter rebuild - how-to (1986 Syncro Vanagon) |
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I think this spring keep the shifter from dropping into the reverse position. This is the spring you are pushing against when you go into reverse. _________________ 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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iheartstrangers Samba Member
Joined: May 19, 2010 Posts: 47 Location: Portland, Maine
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Posted: Sat Aug 13, 2016 8:13 pm Post subject: Re: Shifter rebuild - how-to (1986 Syncro Vanagon) |
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Could you explain further? How am I pushing against it? I just don't understand how it works as it is merely sandwiched between the components of that ball set and the bushing. When is that spring coming into play? _________________ --
My name is Joshua and I am just getting started with an '84 Adventurewagen |
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Stephenmarklay Samba Member
Joined: August 10, 2016 Posts: 526 Location: Spokane
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Posted: Sat Sep 03, 2016 7:39 pm Post subject: Re: Shifter rebuild - how-to (1986 Syncro Vanagon) |
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iheartstrangers wrote: |
Could you explain further? How am I pushing against it? I just don't understand how it works as it is merely sandwiched between the components of that ball set and the bushing. When is that spring coming into play? |
Belated:
I "think" the spring acts like a retainer. With the shifter lever arm you could apply enough force pushing into gear that you could pop the top hemisphere out of the assembly. The rather robust spring is still pushing down on the assembly as you are pulling it away and keeps it all together. _________________ 1985 Westfalia. Project 2017. |
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Stephenmarklay Samba Member
Joined: August 10, 2016 Posts: 526 Location: Spokane
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Posted: Sat Sep 03, 2016 7:46 pm Post subject: Re: Shifter rebuild - how-to (1986 Syncro Vanagon) |
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I took my ball all apart cleaned and lubed it all. Nothing was broken and it looks fine. Very smooth now.
For the life of me I don’t know why there is not a gasket between the base plate on the assembly and the body. I have a wee amount of surface rust on the inside lip of the van and my van is pretty rust free. I imagine vans that see a lot of road salts that this area is a bit more rusty.
I am going to use a small amount of body caulk on underside when I put it together. _________________ 1985 Westfalia. Project 2017. |
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Gnarlodious Samba Member
Joined: September 28, 2013 Posts: 2323 Location: Adobe Jungle USA
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Posted: Sat Sep 03, 2016 7:48 pm Post subject: Re: Shifter rebuild - how-to (1986 Syncro Vanagon) |
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The spring keeps the ball tight. The breakage symptom is when the enclosing sphere pops apart and the spring isn’t restrained the ball jumps up and down pretty bad. You can still drive but the linkage is all loose and it takes some practice. I suspect there are Vanagon drivers who think that’s normal and don’t realize esomething is broken.
The moral of the story is, if you buy a Vanagon and you can drive it but the shifter is all loose, it probably needs this fix. _________________ Vanagon ’83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit |
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Stephenmarklay Samba Member
Joined: August 10, 2016 Posts: 526 Location: Spokane
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Posted: Sun Sep 04, 2016 4:48 am Post subject: Re: Shifter rebuild - how-to (1986 Syncro Vanagon) |
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It’s kind of a mystery to me why VW did not close off the back of the shift guide box and use a rubber boot. Why have this area open for gunk to get in the way of smooth shifting? _________________ 1985 Westfalia. Project 2017. |
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