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Home >> Volkswagen >> 1984 >> Vanagon Base, Standard >> Repair and Diagnosis (Single Page) >> Transmission >> Manual Trans >> Overhaul - 091 & 094 >> Adjustments >> Shift Fork Adjustment

Shift Fork Adjustment

NOTE: Shift fork adjustment is made with Adjuster (VW294b). Tool consists of the following: Mounting Plate (VW294b/2); mounting plate-to-gear carrier Spacer (VW294b/4); pinion Retaining Ring (VW294b/7); reverse gear Spacer (VW294b/10); and 2 bolts to hold gear carrier to mounting plate. 4-speed
  1. Attach assembled gear carrier, with pinion shim, to Adjuster (VW294b). See Fig 1 . Tighten Retaining Ring (VW294b/7) by hand. Install shift forks for 1st-2nd and 3rd-4th gears.
    NOTE: Install flat side of 1st-2nd shift fork away from gear carrier. Install flat side of 3rd-4th shift fork toward gear carrier.
  2. Install relay lever support and relay lever. Place 1st-2nd gear selector in 2nd gear position. Slide operating sleeve, with fork, over synchro teeth until it is against 2nd gear. Center shift fork in groove of operating sleeve and tighten clamp screw.
    CAUTION: Shift fork must not rub or press against sides of groove in operating sleeve when in neutral position. Clearance must exist.
    Fig 1: Assembled View of Shift Fork Adjustment Tools
    G95H55787Courtesy of VOLKSWAGEN UNITED STATES, INC.
  3. Select 1st and 2nd gear position several times while turning mainshaft. Check clearance of shift fork in operating sleeve in each position. If necessary, reposition shift fork until there is same amount of clearance on selector shaft in both end positions, then tighten clamp screw to 18 ft. lbs. (25 N.m).
  4. Place 3rd-4th gear selector shaft in 3rd gear position and adjust 3rd-4th gear shift fork in same manner as 1st-2nd.
    CAUTION: For correct adjustment of 3rd-4th gears, mainshaft bearing must be pressed fully into gear carrier housing.
  5. Place reverse gear selector shaft into reverse gear position. Adjust reverse gear so that sliding gear is fully in mesh with teeth on operating sleeve for 1st-2nd gear. Tighten union nut on relay lever support.
  6. Shift out of reverse gear and press sliding gear lightly toward gear carrier. Clearance between reverse gear and 2nd gear on mainshaft must be a minimum of .020" (.5 mm).
  7. Engage 2nd gear and check clearance between operating sleeve and reverse sliding gear. Adjust if necessary. Check interlock mechanism. When gear is engaged, it must not be possible to engage any other gear.
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