Date:         Sun, 13 Jun 2004 09:06:34 -0700
Reply-To:     Daryl Christensen <aatransaxle@DIRECWAY.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Daryl Christensen <aatransaxle@DIRECWAY.COM>
Subject:      Re: Syncro linkage problem
Content-type: text/plain; format=flowed; charset=iso-8859-1; reply-type=original

Al, et all...The later tranny gear carrier housings were updated around 88
by VW with wider bosses where the linkage plate bolts to the trans so the
linkage rod wouldn't bottom out and keep it from fully engaging 2nd or 4th.
There was a tech bulletin I was told that says put a pair of 6mm washers
between the plate and the housing bosses to give some more room for the
"float" of the shift rod. The only ones I have seen with the problem are
ones with the rubber accordian boots still intact. The rubber gets
compressed adn tries to push it back out of gear.
 Kinda confusing I know until you look underneath at the setup to see what I
mean...Hope that helps someone.
Daryl of AA Transaxle
Duvall, WA. (Seattle area)
1-877-377-0773 toll free
425-788-4070
aatransaxle.com


> Anyway inquire of a good rebuilder how to determine this float.  The
> defect
> occurs when the plate
> to which mark refers pushes against the shift rod slightly enough to
> partially disengage the gear under load.




----- Original Message -----
From: "Al Knoll" <al_knoll@PACBELL.NET>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Saturday, June 12, 2004 10:14 PM
Subject: Re: Syncro tranny problem


> Mark said:
>
> Date:    Fri, 11 Jun 2004 18:46:51 -0700
> From:    mark drillock <drillock@EARTHLINK.NET>
> Subject: Re: Syncro tranny problem
>
> This is a very common error. You likely attached the linkage wrong at
> the tranny. The plate that bolts to the ears on the tranny can be bolted
> to the wrong side of the ears quite easily. When you do it wrong there
> is not enough travel available to bet all of the gears to engage. With
> the shifter in neutral, look at the rub/wear area on the shift rod at
> the tranny bushing. You should see an equal amount of wear/rubbing marks
> on both side of the bushing. If not, take the 2 bolts out and move the
> plate to the other side of the ears.
> ~~~
> I will add one more note to the wisdom above.  Make sure that there is
> enough "float" in
> the shift linkage.  As the van accelerates and decelerates the
> transmission
> moves forward
> and aft.  If there is insufficient float, second and fourth gears can run
> only partially engaged
> and will wear out very quickly.  A transmission R&R done at a shop not to
> be
> named forgot to
> check this all important item on a transmission that I had just had
> rebuilt.
> Fourth gear failed
> after 1600 miles and began to "pop" out of gear under acceleration.  Cost
> me
> another rebuild and
> the shop refused any help in the matter claiming the shift linkage is "not
> adjustable".  Not so
> of course.
>
> Anyway inquire of a good rebuilder how to determine this float.  The
> defect
> occurs when the plate
> to which mark refers pushes against the shift rod slightly enough to
> partially disengage the gear under load.
>
> I highly recommend as I have done in the past, Jeff Field at Transaxle
> Engineering in Chatsworth for
> consultation and repair.  He did both rebuilds for me and the second one
> is
> doing just fine after
> a bazillion miles with a properly adjusted linkage.
>