Gear selection adjustment ?

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Velgreeno

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Hey all. Im having probs with getting third to second on my 68. Everything is new from the bushes, cable, box itself etc etc to the plate and spring in the stick but just cant get the adjustment right. Does anyone have any pics of theirs adjusted perfectly ? Ive done the put in second and tighten but still not right. They all engage great but pulling up and going from third to second can be tricky and crunch sometimes. Ive adjusted the cable too. Its definately the stick adjustment i think but if anyone could post up a pic of their gear stick assembly and where its bolted down then that would be great. Cheers.
 

sparkywig

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All buses are different, so what is a perfect shift for one won’t even engage 1st for another.

Try adjusting the gear shift again, put it into 2nd gear, loosen the two bolts holding the base of the gearshift and move the gearstick so that the bottom bit is vertical and the cranked bit is at 30 degrees to the rear of the van. Then move the shift plate as far left as possible without moving the gearstick. Tighten the two bolts. This should help selection of 1st and 2nd.
If the lever doesn't travel straight forward and back in the 1st/2nd plane, try slightly twisting the shiftplate.

If this doesn’t work make sure the front shaft bush under the gear stick is OK, check the collar attaching the two shift rods is secure, then the rear shift coupler at the gearbox.
If the bushing is worn at the rear coupler this can give poor gear selection.
 

Velgreeno

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Cheers for that Sparky. I've tried with it all and here's what I'm left with. I can get all gears fine going up and then going down but going down there seems to be a kind of obstruction from third to second. Also I got pics like it is now. Does this look ok ? Check the vid too shows what I mean. cheers.
 

Velgreeno

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This is the pics and vid just taken. Cheers.
 

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Velgreeno

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In the vid there dont seem like there's a prob but there is. Grr frustrating ha.
 

sparkywig

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Gear shift looks fine, the problem with probably be with the rear coupler to the gearbox. Items 25 and 27/29 wear. Try and use the existing cage (23) if it's original.


18 is the front bush, and 13 is the rear bush that's only accessible by removing engine/gearbox and withdrawing the shift rod through the engine bay.
 

Velgreeno

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Cheers Sparky. The rear coupling is new and replaced it when i installed the brand new gearbox last April because it disintegrated litterally in my hand. Ive actually been under there today and oiled everything moving ha and on the front number 18 on your diagram, thats loose and the rod inside does have play in it and i can move it about. Maybe this is the problem perhaps. And i have never replaced that one. I think i better order that front rod bush.
 

JohnVW

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If it helps it took me a while of minor adjustments to the plate to get gear selection spot on. A small movement seems to translate to a bigger movement by the time it gets to the gear box ! Not sure if it made a difference but I put my old plate back on.
 
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I went through my rods/bushes/couplers and although the shift is acceptable, I still have wear in the gearbox nose cone bush that I’ll have to check whilst I have the motor out. It might be worth checking if you have play there?
As an aside, replaced the front gear rod bush on mine- the new bush is plastic and still felt a little sloppy. I wondered about machining a bush from brass or phosphor-bronze with a better sliding fit? Any thoughts? Anyone tried it?
 
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Moseley

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I went through my rods/bushes/couplers and although the shift is acceptable, I still have wear in the gearbox nose cone bush that I’ll have to check whilst I have the motor out. It might be worth checking if you have play there?
As an aside, replaced the front gear rod bush on mine- the new bush is plastic and still felt a little sloppy. I wondered about machining a bush from brass or phosphor-bronze with a better sliding fit? Any thoughts? Anyone tried it?
It’s something I’ve wondered myself; the last front bush I bought was a disgraceful quality, but in fairness the vendor did send another better one to replace it (makes you wonder why they had two types on the shelf?) Even that one had a good amount of slop in it, and a few years later it has noticeably disintegrated despite being substantially greased. It seems like a good project for Buttys Bits to come up with a more-robust solution, as you say, phosphor bronze, or I wonder if a small roller bearing could be press fitted into a recess? Possibly not enough space to machine it out.
 
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It’s something I’ve wondered myself; the last front bush I bought was a disgraceful quality, but in fairness the vendor did send another better one to replace it (makes you wonder why they had two types on the shelf?) Even that one had a good amount of slop in it, and a few years later it has noticeably disintegrated despite being substantially greased. It seems like a good project for Buttys Bits to come up with a more-robust solution, as you say, phosphor bronze, or I wonder if a small roller bearing could be press fitted into a recess? Possibly not enough space to machine it out.
I think it would have to be a bush due to needing to both slide and rotate. I would also think the problem for commercial production might be securing it, I would probably do an interference fit which is ok as a one-off, but might be tricky allowing for various rods that could have corrosion or be aftermarket parts. Might have a look at that.
 

Velgreeno

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Cheers for the further replies folks. Well i am in the process of changing the front bush now. Apart from stabbing my finger getting the old bush out of the front shaft and blood everywhere ( school boy error i know ha). The screw top on the linkage collar decided to snap off so im about to order a new one. Still. So far so good. Bush changed, fresh grease etc just got to wait for a new screw now and then put it all back together and then adjust the gear shifter and then hopefully that will be it.😳.
 

Velgreeno

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Tell you what folks. Don't you just love it when you have one of those ahh lets order another one of those parts because you never know when you will need it as a spare moment. Well in my treasure trove bus parts cabinet i have found a new screw for the collar. Apparently its the same as the back coupling so thank you very much past me for thinking ahead ha 😄. No guessing what il be doing inthe morning 😊.
 

bmxburner

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I just did mine on Sunday. Depressingly, it seemed to have the same amount of slop after replacing the front bush, the brand new one seemed just as loose as the old one. Moved to the back and took off the rear coupler there. I could see no markings on the cage, but I think I could make out VW on the black rubbers. They looked in pretty good condition, but the metal bolt did have dents in it where it was worn against the shaft. I replaced this with an EMPI one I had in the parts box, it has the red urethane rubbers. Keeping the old one on board as a spare though. There is definitely less rotational movement with the new one, so it seems a bit better. I'll take it for a test drive tomorrow.
 

Velgreeno

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Well i just got it all back together now. Got in and no gears. I thought ohh bugger whats causing this. Anyway a bit of inspection later and a few trips under the bus, it turns out i bolted the front shaft in too far. I pulled out slightly and screwed the bolt in the first hole and so far touch wood all the gears are back and a bit more adjusting and packing it all with grease then she should be ok. Its strange though theres 2 holes on the front shaft though, the second makes it too short. It must be a splitty part maybe because my bus is feb 68. Odd. Anyway hopefully il be back on the road soon, going to have to adjust properly tomorrow now because work becons ha.
 

Velgreeno

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Hey all. Well jobs all done,, adjusted,the best i can get her, cleaned and everything regreased with fresh and so far she's running very smooth and that bush nas made a good difference and so far (touch wood.) She's running good with no probs 🤙.
 

Velgreeno

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Hey all. Well I took her to work again yesterday and third to second was not good again. Theres nothing i havent replaced from gearbox (new) to clutch and bushes etc and adjusted. Really baffling me now. She engages gears when engine is on and off sationary. So strange...
 

mike202

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I had a similar issue when I had the new engine /recon gear box. I literally changed everything; gear stick, front bush, front gear shift rod, gear shift rod coupling ring, gear shift coupling, new springs in the rear selector rod bushes.
I still found it difficult getting second from third gear. I could even get reverse by accident if not super careful. I asked Paul at the garage to look at it and he fixed it for me. He said it just needed to be correctly adjusted. I had tried everything!
 

Velgreeno

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I had a similar issue when I had the new engine /recon gear box. I literally changed everything; gear stick, front bush, front gear shift rod, gear shift rod coupling ring, gear shift coupling, new springs in the rear selector rod bushes.
I still found it difficult getting second from third gear. I could even get reverse by accident if not super careful. I asked Paul at the garage to look at it and he fixed it for me. He said it just needed to be correctly adjusted. I had tried everything!
Cheers for the reply Mike. I think mine just needs a good adjusting. Its definately from the shifter i think or that's how it feels. Theres only me and no one to help unfortunately and i have nothing to go on really to compare and would never trust a garage around where i live because they have no clue. Im off work tomorrow so im going to have another go. I think it might be the plate but ah who knows 😕.
 

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