2nd gear synchro

[Royal]

My 2nd gear synchro is nearly shot. Only noticeable on slamming it into 2nd while downshifting from 3rd. I’ve been reading on Samba and in my Bentley and am considering pulling the transaxle and attempting a rebuild (or at least replacement of the synchro(s).

My experience in this area is limited and it was a long time ago. Never did a VW transaxle. Have done Sunbeam and MGTF transmissions but that was 40 years ago.

Now I am 73 and am most worried that if I get it apart, and have to order something which takes 4 wks to get delivered, I may “lose my place”x and forget something.

I’m asking for advice from any of you that have done this kind of work. I have changed to synthetic gear lube with no change in shifting. Hardly any metal on the magnetic drain plug.

I need a winter project to keep me out of the bars. I could:
1. Read War and Peace, and continue to drive as is.
2. Pull and attempt repairs myself in my humble garage.
3. Pull and take to a pro. I have no idea of $$ expected and you probably guessed (correctly) that I am very retired (limited income). And I’m pretty much a do-it-yourself kinda guy anyway.

What say you?Royal2014-09-23 22:20:46

[edward ericson]

How are you so sure it’s the synchro? Do you have a 1st gear synchro? 

I chose to have my trans done by the guy who did Cory Drake’s box and, though it cost me $1100 all said and done I have not yet regretted it. That said, if I had more time than money I would now consider trying my hand at it. And if I had already gone through a couple transmissions I would almost certainly try it. 

You, Roy, I have full confidence in.

[Royal]

Why 2nd gear synchro? Shifts great except for downshifting into 2nd. My experience tells me that that’s 2nd gear synchro prob. Am I wrong?

[edward ericson]

No idea. I suspect you are right.

But I have noticed on my car, even now with all new synchros & such, the downshift to second is not always smooth. Basically I’m blipping the reverse, I think, and it sounds positively brilliant. I suspect it is a combo of just-slightly-off shifter adjustment and general shifter-is-sloppy. In my case I can get it to shift perfectly after trying and missing a time or two. Just need more stick time so I get into the habit of hitting the gate right. 

If your upshift is always good (as mine is) I wonder if it absolutely has to be the synchro.

[Royal]

It’s true that the shift down into 2nd does engage the 1st/2nd fork.
I suppose it could be a sloppy or maladjusted shifting mechanism. Maybe even that little shift rod guide at the base of the shifting lever??
I’m really going to be embarrassed if that’s all it is.

[davearoy]

I replaced the plastic shift rod bearing (located just under the stick shift base plate. I had to remove the shift rod out of the tunnel to replace it, because the bracket holding the plastic bearing has a circular slot that the bracket fits in. I also replaced the 2 plastic square pieces in the shift rod yoke (the yoke attaches the shift rod and the transmission shaft together). Fortunately I did this during my “off body” chassis revocation. I am glad I did both, as it really has tightened up the shift assembly.

Dave

Dave
Lakeland, Florida, where we drive Topless every day

[edward ericson]

Yep! Good on ya Dave. Shift busing and coupler were two of the first things I did on mine. Terrible PITA but well worth the effort.

[KentT]

I would certainly try repairing/replacing the shifter linkage before I yanked the engine and transmission…

You could likely get a rebuilt tranny as cheap as you could pay the labor (and learning curve) for someone local to repair it, unless they specialize in VW trannies…

Then, you could specify the gear ratios (each gear, plus R&P) that you wanted, in addition to adding HD side plates, super-diff or whatever, until you emptied the checkbook…

Early FF TDr on 69 VW pan
Slowly coming back from the ashes...

[Author]

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