Where is 2nd Gear? **RESOLVED**

[drober23]

1975 Westfalia camper. 2.0L engine, just swapped a 091 transmission into it.

When I hooked it up (before adjusting anything), I could get 1, 3rd, and 4th easily. I could find reverse with a bit of fussing. No 2nd at all.

I mucked around with the stop plate, and was able to get 2nd, but then I only had 1st, 2nd, and reverse. Looks like I can get all the gears, but not all at once

Poked my head under the bus, and realized the front shift rod bushing was gone. Installed one today. Shifts a bit nicer, but still can't get all the gears at the same time.

Now for a couple questions.

1) The Bentley manual says to get it in 2nd, then adjust the gearshift handle so that it is at a 90° angle from the floor of the bus. Does that mean vertical (90° from every place you can put the square) or just from left-right ways?

2) Am I missing something simple to check? I spent a good couple hours searching and read a bunch of threads before positng.

3) Does anyone have any stop plate adjusting secrets to share?

Thanks for any help you may have.
_________________
DJ

'75 Westfalia, '79 Deluxe, and some others...
(more busses than sense)

In a time of chimpanzees I was a monkey

[Wildthings]

The shift coupler isn't hitting the crossmember in front of the transmission is it?

[SGKent]

As close to vertical as possible. Did you inspect the coupler, front bushing under the shifter area and donut in the nosecone?
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“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[Desertbusman]

[drober23]

Thanks for the tips! I'll look into those this evening when I get home.

Wildthings: I didn't think to check about it hitting the crossmember. I'll re-read some threads on swapping in an 091 and check that.

SGKent: New front bushing (under the shifter), new coupler. Did not inspect the donut in the nosecone.

Desertbusman: Thanks for the secret
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DJ

'75 Westfalia, '79 Deluxe, and some others...
(more busses than sense)

In a time of chimpanzees I was a monkey

[drober23]

I think Wildthings is onto something here. I had read the quoted post in the past, but somehow managed to forget it. The 091 transmission is longer than the 5-rib that I replaced.

[drober23]

The 091 Transmission is about an inch longer than the 5-rib transmission I replaced it with. When I just slapped it in, I could not get 2nd, and reverse and 4th were dicey.

I did not do anything with the shift rod length. So today I removed the front-most grub screw, and pulled it apart. Then I drilled a new "divot" in the shaft, about an inch behind the existing divot. I lined the shaft back up, and tightened the grub screw (and replaced the retaining wire) which effectively shortened the shaft an inch.

Now I can get all my gears! But, the rear coupler was banging against the crossmember it passes through near the transmission. I only needed to deflect the crossmember about 1/4" forward to keep it out of contact with the coupler.

I have all my gears now! The whole pattern is shifted a bit further forward than I am used to, but nothing is uncomfortable to reach. 3rd does get a little closer to the parking brake handle than I would like though.

If I decide I don't like it, I may try drilling yet another divot halfway between the two and see if I can still get all my gears.

Thanks for the advice and ideas!
_________________
DJ

'75 Westfalia, '79 Deluxe, and some others...
(more busses than sense)

In a time of chimpanzees I was a monkey

[Desertbusman]

Cool
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71 Superbug
71 Westy

[aeromech]

I'm glad you have your bus moving. Have you considered a bend in the gear shifter so the knob doesn't hit the parking brake handle?
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[Wildthings]