Strange shifting issue

[ozzmonaut]

So this one seems odd to me, only because it isn't one of the problems I generally hear about connected to vw's. I was on a trip and all was going well. Leaving a stop light, 1st gear wasn't 1st. It felt like 3rd. I freaked a little bit, fearing my clutch was out. I pulled it into 2nd and went back to 1st, same problem. I gassed it some and went on through the light and pulled over in a parking lot. I went to 3rd to make sure I wasn't somehow shifting incorrectly. Went back to 1st and it was still 3rd. I went to 2nd and back to first again and all was suddenly right. It happened a couple more times during the trip, which was a few hours total.
My best guess is that there is some slop in the shift rod coupler, allowing the shift lever to sometimes move to 3rd gear when I go to 1st. Has anyone had this experience? The coupler looks ok, not outstanding, but not overly worn or damaged. Still, I feel like this is the best chance. Thanks for your help

[SGKent]

so how do plan to fix it?
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[aeromech]

A coupler can look ok but not be. Did you watch it while a partner shifted through the gears? Also, check the forward shift rod bushing. What year?
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[Tcash]

Shifter Parts ID T2

[ozzmonaut]

It's a 69. I'm not sure how I'm going to fix it, because the cause of the problem is not identified. That's why I want to see what experiences others have had. I don't have anyone to shift while I watch.
I have never heard of the shift rod bushing causing an issue like this. Maybe harder shifting, but not missing 1st gear. Then again, I have never heard of a worn coupler causing this, either. Has anybody else had a similar situation? Specifically, moving the shifter to the 1st gear position and having it pull the trans into 3rd? Thanks

[SGKent]

you can either replace all the parts, or you can have someone help you while you look over each part for freeplay. It can be one broken part or many worn parts. That failure has many different flavors, you have to check for each one starting with the easiest first:

bad bushing up front
Pin fell out
shift stop plate in pieces
loose grub screw(s)
bad coupler bushing
coupler spinning
worn out ball in nosecone
broken selector bracket inside transmission nosecone
gears have moved out of place due to main bearing wear
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[airschooled]

What year car is this? I'm assuming it's a bus, because…

In 1976 VW introduced a spring-loaded neutral system that lines the shifter up for first and second without any lateral input from the driver. Unfortunately, on these transaxles, ANY slop in the coupler, bushings, or shifter itself will be taken up by the springs and your shifting input will not be translated back to the transaxle. If you have a later bus, every part MUST be accounted for, intact, and adjusted correctly for precise shifting.

Earlier buses can get occasional clean shifts even with missing bushings. But seeing as they don't make these transaxles any more, occasional doesn't really cut it.

You WILL need a helper to diagnose this issue. They don't have to know how to drive a VW. They don't even need a license; if they can correctly follow simple instructions, you'll be good. It goes something like this:

You crawl under the bus and watch every part of the shift mechanism, from front to back, while you instruct the assistant to move the shifter GENTLY
"forward" "back" "right" "left" or "neutral." With your best seeing-eye glasses if necessary, look at every part of the shift rod system for signs of movement discrepancy.

Here is discrepancy between the input and output of a shift coupler:


Link



Here is a worn out bushing on a '71 bus:


Link



A later bus will have a front shift rod that looks slightly different, but the absence of a bushing is more likely due to the design and age of these vehicles.

Good luck!
Robbie
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[Amskeptic]

[aerosurfer]

Start simpler... jave you just checked that your shift plate on the floor isnt loose or has moved on you?
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[ozzmonaut]

I did check the shift plate. It was good. But then I was underneath just looking at the situation and decided to just use the coupler to push/pull the shift lever in and out. I noticed that as I twisted the coupler to mimic going from 1st/2nd positions to 3rd/4th that the coupler could move on the shift lever. So, indeed it appears the grub screw was a hair loose. I tightened it, but we have a pile of cars in the driveway, so I can't get out to take a drive. But I will tonight. It tightened down substantially, but did not come to a hard stop, so I fear the threads might be slightly stripped, and did not want to over-do it. At least then I would know what is occurring and can replace the coupler.

[mikedjames]

The screw is pointed on the tip and goes into a hole with a dish at the bottom so it just sort of gets tighter.
Then get out the champagne cork or prosecco iin EU (or local dry sparkling wine) take the wire off it and use it to lock the screw.
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[Tcash]

Heavy duty shift coupler
https://www.jbugs.com/product/16-5105.html

[airschooled]

The grub screw land in the shift rod MUST be clean for the grub screw to take torque and hold. Ask TheBusAndUs about fixing theirs at the beach in our wetsuits…

Robbie
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[ozzmonaut]

The hole was stripped. Not sure how. Grabbed another coupler from a friend the other day. All is well. Wire was gone so a bicycle spoke is in place and shifting is good and tight again.