Date:         Mon, 5 Jun 2000 00:43:01 -0400
Reply-To:     Dave Katsuki <dkatsuki@WORLD.STD.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Dave Katsuki <dkatsuki@WORLD.STD.COM>
Subject:      Transmission shift linkage adjusting
Content-Type: text/plain; charset="us-ascii"; format=flowed

While I'm thinking of it, thought I'd document my efforts in adjusting the
shift linkage on our 90 Westy.

After I had the transmission replaced (low mileage unit from junkyard)
recently, it was hard to get into first.
I needed to depress the know and move it slightly into the reverse gate to
get it into first (but not second usually).

Since this seemed like a simple adjustment, I just loosened the coupling in
the shift rod (after carefully marking the original position), and moved
the lever at the transmission end slightly toward the reverse side, and
then tightened it.   What could be easier?   Unfortunately, it still needed
to be pushed slightly into the reverse gate to get into first.   So a
little more adjusting in the same direction.   Needed still
more.   Adjusted a little more.   Now could get into first, but couldn't
get into reverse, and third was funny.   Arrrghh!   Finally in desperation,
I decided to follow the adjustment procedure in Bentley exactly, and wonder
of wonders, ALL the shifting problems went away!   Perfect shifting, and
has remained that way for the last 500 miles!

Here's what I did, folks:

Bentley calls for a 23 mm spacer (several different sizes, depending on the
year of your van), and they suggest metal, but I made a 23 MM spacer by
sanding down a 1/4 " thick piece of wood to be as close to 23 mm wide
(parallel & vertical sides) as I could get it.  I suspect +/- 1 mm is
fine.  The piece ended up being 23mm by maybe 30 mm with a short
handle.  Length isn't critical. but I wanted something to grab.

Then jack the front of the car up as high as possible and take out the
spare.   Loosen the coupling on the shift rod.
When you get under the front of the car with your back in the spare tire
carrier and your head as far up as possible, you can just see into the open
end of the shift housing (where the shift lever comes down).   Try to get
the end of the shift lever roughly centered front to back in the shift
housing.  Now place your precision 23 mm (or other appropriate sized)
spacer between the end of the shift lever and the stop (right side, looking
toward the front), and then tie a wire or string around the shift rod and
the nearby radiator hose, to keep the spacer in place.   Scoot around under
the middle of the van and make sure that the shift lever at the
transmission end of the shift rod is vertical, and then tighten the
coupling.   (Make sure the spacer didn't drop out during the
tightening.)    Take the wooden spacer out and check the shifting.

This took me about 10 minutes after making the spacer and jacking the car
up, and it was perfect the first time!   Couldn't believe how easy it was.

Dave
90 Westy