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Date:         Tue, 18 Feb 2025 07:40:31 -0800
Reply-To:     mark@MARKMCCULLEY.COM
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Mark McCulley <mark@MARKMCCULLEY.COM>
Subject:      Re: rebuilding shifter linkage
In-Reply-To:  <D8D7391A-9F91-43CE-B39F-9E5B4D90E230@markmcculley.com>
Content-Type: text/plain; charset=utf-8


I adjusted the linkage slightly, maybe 1/2 the width of one of the splines on the front rod. This got me spot-on with the 23mm as detailed in the Bentley. 


A test drive showed that the noise I was hearing through the shifter is now mostly gone.


I'm calling this project complete, I'm happy with the shifting and like how the GW quick shift kit reduces the travel of the shifter when changing gears.


-Mark


> On Feb 15, 2025, at 12:04 PM, Mark McCulley <mark@MARKMCCULLEY.COM> wrote:
> 
> Thanks, I did see that. I will test again once I tweak the linkage a little bit.
> 
> -Mark
> 
>> On Feb 15, 2025, at 10:24 AM, Dan N <dn92610@GMAIL.COM> wrote:
>> 
>> Maybe this would help a bit?
>> 
>> https://www.thesamba.com/vw/forum/viewtopic.php?t=665217&highlight=shifter+rod+making+noise
>> 
>> On Sat, Feb 15, 2025 at 9:42 AM Mark McCulley <mark@markmcculley.com <mailto:mark@markmcculley.com>> wrote:
>>> Yes it is fussy. Unfortunately I don't have an assistant to help. I'm following the method in the Bentley manual, the 23mm measurement, not so hard to do alone. 
>>> 
>>> -Mark
>>> 
>>>> On Feb 14, 2025, at 4:04 PM, Richard Koerner <rjkinpb@sbcglobal.net <mailto:rjkinpb@sbcglobal.net>> wrote:
>>>> 
>>>> I'm not sure if this will be any help at all....but shifter linkage adjustment is fussy, it just is.  A 2 person job really; one guy in Captain's chair, one guy down below.  You holler back and forth!  NOPE....now no good in 1st and 2nd....Nope, now no good in 3rd and 4th..  OK....let me try Reverse....HOLD it right there, everything is working!
>>>>   On Friday, February 14, 2025 at 03:35:24 PM PST, Mark McCulley <mark@markmcculley.com <mailto:mark@markmcculley.com>> wrote:  
>>>> 
>>>> I've made a recording of the noise I'm hearing from the shifter. I made the recording by holding the phone a couple of inches above the shifter knob so the noise in the recording is louder than what I actually hear. 
>>>> 
>>>> First I run through the gears and show how putting my finger on the knob makes the knob go away. Then I remove the shifter knob and do another recording showing that the noise completely goes away. Lastly I replace the shifter knob and run through the gears again.
>>>> 
>>>> Anyone should be able to access the recording at this link: 
>>>> 
>>>> https://drive.google.com/file/d/1-YmA17ind3T4YVvZsMPUxLyq7uteuZUO/view?usp=share_link
>>>> 
>>>> My next step is to try a different shifter knob.
>>>> 
>>>> -Mark
>>>> 
>>>>> On Feb 14, 2025, at 11:18 AM, Mark McCulley <mark@markmcculley.com <mailto:mark@markmcculley.com>> wrote:
>>>>> 
>>>>> I was rebuilding the shifter linkage due to worn bushings.
>>>>> 
>>>>> I'm not feeling any vibrations, just hearing a noise emanating from the shifter. The noise is loudest in 2nd, can also hear it in 1st, don't hear it in 3rd or 4th. The pitch of the noise changes with RPMs.
>>>>> 
>>>>> I don't think the transmission is making abnormal noises, it's just that sounds from the transmission are being transferred through the linkage and shifter into the cabin. The shifter knob is acting as a resonator. Just touching the center of the knob with my finger stops the noise. Removing the shifter knob stops the noise.
>>>>> 
>>>>> My working theory is that the knob is hollow and is acting as a resonator with the top of the knob as a diaphragm. GW warns about the hard Teflon bushings conveying more noise, that's likely a factor here as well.
>>>>> 
>>>>> 
>>>>> 
>>>>>> On Feb 14, 2025, at 10:42 AM, Dennis Haynes <d23haynes57@HOTMAIL.COM <mailto:d23haynes57@HOTMAIL.COM>> wrote:
>>>>>> 
>>>>>> Were you repairing the shifter linkage due to worn bushings and a shifting problem or an attempt to silence the vibration? 
>>>>>> Is the vibration in all gears, 1 and 2, or 3 and 4? Does the vibration change with throttle change? 
>>>>>> In 3rd gear, light hand pressure pushing shifter forward, does the shifter push back when throttle applied and then move forward when throttle released? 
>>>>>> Did you check the front trans mount is good?
>>>>>> 
>>>>>> Dennis
>>>>>> 
>>>>>> 
>>>>>> -----Original Message-----
>>>>>> From: Vanagon Mailing List <vanagon@gerry.vanagon.com <mailto:vanagon@gerry.vanagon.com>> On Behalf Of Mark McCulley
>>>>>> Sent: Friday, February 14, 2025 9:16 AM
>>>>>> To: vanagon@GERRY.VANAGON.COM <mailto:vanagon@GERRY.VANAGON.COM>
>>>>>> Subject: Re: rebuilding shifter linkage
>>>>>> 
>>>>>> I have an update on the shifter linkage work. Everything is back together and I did a test drive yesterday. I'm not fully happy with how it shifts yet, think I need to do some fine adjustment on the linkage.
>>>>>> 
>>>>>> I chose to use the hard Teflon bushings and Viton rubber boots from GW. Another option was bootless pliable bushings from VC but I wanted to have boots. I did not use any lubrication on the Teflon bushings.
>>>>>> 
>>>>>> During the test drive I noticed something odd...that removing the shifter knob eliminated all of the transmission-related noise that was being conveyed from the transmission by the linkage. No knob, no noise, very strange. I'm going to play around with this some more, maybe try a different knob from the OEM one I'm using. I also may try adding some damping to the shifter rods and see if that makes any difference.
>>>>>> 
>>>>>> -Mark
>>>>>> 
>>>>>>> On Jan 31, 2025, at 9:24 AM, Mark McCulley <mark@markmcculley.com <mailto:mark@markmcculley.com>> wrote:
>>>>>>> 
>>>>>>> I've started a winter project of rebuilding the shifter linkage, from the shifter to the transmission. This will be the second time I've done this project on this van, it's been at least 100K miles since I did it the first time.
>>>>>>> 
>>>>>>> I spent a couple of hours under the van yesterday removing all of the linkage parts. It was a bit troublesome disconnecting the front and rear shifter rod sections but I managed to get it done. The next step is to remove all the undercoating on the two rod sections. I had undercoating applied about 20 years ago. I think I'm about 60% through with that messy endeavor. 
>>>>>>> 
>>>>>>> I also plan to replace the shift lever with one that is solid and install a short shift kit.
>>>>>>> 
>>>>>>> -Mark
>>>>
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