1992 Eurovan. How do I repair manual shift relay linkage balls?

[bobinyelm]

'92 Eurovan 5spd Manual Trans

The relay rod (horizontal rod w/ nylon balls at each end-looks like a dumb bell) detached from perished retaining bushing (at transmission end).

I have the diagram, and read a hit to use aluminum wire for a temporary fix, but unsure how to repair it in-place with new bushing for inner ball socket.

Would appreciate advice from anyone who has done the repair! I am hoping the new bushing can be hand press-fitted into the bracket, and the rod be levered inboard to pop the ball (maybe lubed w/ some silicon grease) to the left and into the bushing (from the top of the engine compartment w/out extensive disassembly), but I'd like to hear from anyone who has done it.

There is so much "stuff" in the way, it's hard to even reach the spot, much less work on it! It would be easy if the engine was not installed but even getting one hand down there is a pain!

I did some searches, but no luck.

The part that deteriorated is the bushing shown as part of #45 in the image below. It does not appear there is anything holding the ball into the other (rectangular) end in Part #49? The deteriorated bushing is shown in my hand.

The actual rubberized bushing pressed into #45 (into which the ball#42 if fitted) is VW/Audi Part # 701711166, and I just ordered one from ECS Tuning if I can persuade it in somehow.

In the photo, the ball that must be fitted into the bushing is that tiny white dot in the middle of the photo, kind of above and left in the bend of the heater hose, and up and to the right of the bend in the brake booster hose, and down below. The bracket for the bushing is next to the ball. "UP" in the photo is actually looking left in the vehicle, and the left in the photo is toward the front of the vehicle.

Thanks,
Bob

[Joshwa]

[tds3pete]

I also removed the bracket that holds bushing #45 in order to install the bushing on the bench. I reinstalled the bracket in place then forced the plastic ball into it using a wooden lever.

It’s a pita to work in there. I found both plastic balls showed little wear so I did not replace them.

I now carry a bushing #45 as a spare. My bushing failed completely on a road trip in Montana, and the car would not shift at all. I found a wood chunk on the side of the road......that plus a couple of zip ties and I was able to jury rig a fix to get me home.
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'58 Westy camper-come and gone
'73 Westy-bought new in Holland,now gone
'86 Syncro weekender-come and gone
'79 Westy...Oscar
'95 Eurovan Camper/5 spd...Marsha Mellow

[Zeitgeist 13]

Just curious but is there any crossover in these parts with Mk3 or Mk4 cars?
_________________
Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[Joshwa]

There’s a similar bushing on the other end of the shift linkage closer to the stick that should be checked also. When that one goes, you lose connectivity to the transmission. Although it is easier to access.
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93 Weekender TDI conversion (AHU)
93 MV TDI conversion (1Z)
Weekender rear cot
Late model cabin air filter on 93
Euro spec bumper install on 93

[Joshwa]

[bobinyelm]

I guess there were two types of balls-soft rubberized ones, and later, hard nylon balls.

The white ones seldom show wear.

[M-BOB]

Hi, I bought a bushing kit from Ebay in the UK like this one:

https://www.cafr.ebay.ca/itm/Genuine-VW-T4-Gear-Li...mp;vxp=mtr

I remember when it broke down, I made a field repair by making a ball out of a synthetic cork wine bottle cap !

Hope this helps.

[bobinyelm]

My balls (the ones on my shift linkage, anyway) are the hard ones (white nylon) and don't appear worn.

The bushing had fallen apart (you could flake it apart with a finger nail), and literally fell out of its bracket when the lip that retains the ball fell away, so I ordered the bushing only.

I'm pretty sure a new bushing will retain the used ball.

[bobinyelm]

[Joshwa]

it's the rest of your picture. Disregard the red markings, as I pulled the image from the web. I was referencing #35, which I've had crumble on me. Also, #24 and #17 can go and you won't likely have issues shifting, but if its worn and your replace it, the shifting will be nice and crisp.

_________________
93 Weekender TDI conversion (AHU)
93 MV TDI conversion (1Z)
Weekender rear cot
Late model cabin air filter on 93
Euro spec bumper install on 93

[bobinyelm]

[Joshwa]

The set that Europarts SD sells, shows they are a different size, which makes sense. In the middle being 45 and the two on the right being the two 35s.

http://europarts-sd.com/item.asp?cID=329&PID=3780
_________________
93 Weekender TDI conversion (AHU)
93 MV TDI conversion (1Z)
Weekender rear cot
Late model cabin air filter on 93
Euro spec bumper install on 93

[bobinyelm]

[squashmeister]

If anyone is still out there ... on my Eurovan 2.5 manual the worst shifter linkage wear seems to be at the base of the lever, ie parts 10, 39 and 35 in the drawing. Does anybody else have experience with this?

[Joshwa]

Yes. I had some sloppiness down there as well. Turned out that I had only one of #17 in place. There should be one on each side of the base of #10 around #39. I put two new #17 and it was a lot better. I had also noticed that #24 had worn, which was causing looseness as well. At any rate, I basically replaced (2)#17 and #24 to fix my own sloppiness at the base of the shifter.

#24
https://europarts-sd.com/item.asp?PID=5256
#17
https://europarts-sd.com/bushing-shifterbasemt1992-1996.asp
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93 Weekender TDI conversion (AHU)
93 MV TDI conversion (1Z)
Weekender rear cot
Late model cabin air filter on 93
Euro spec bumper install on 93

[wannabecamper]

Link
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[SteveZ]

The bushings at 35 on both sides needed replacement when I had trouble shifting, so check and/or replace those while you're at it.