# # ## ## # #### #### # # # #### # # # # # # # # ## # # # # # # # #### #### # # # # # # # # # # # # # # # ### # # # # # # # # # ## # # # # # #### #### # # # #### # ####### # # # # # # # # # ## # # # # # # # # # #### # # # # # # # # # # # # ## # # # ####### # # # # # ####### Some interesting tips and tricks related to the VW A1/A2/A3 gear shifts: From: http://www.faqs.org/faqs/autos/vw/technical-faq/ Q: How can I improve shift effort/meshing of my gears? First gear feels like there is something blocking it? A: First check out the linkage adjustments, regrease where needed, and older cars, possibly replace the old linkages/bushings. A special spacer tool is needed for one of the adjustments (A1 & A2) which happens to be exactly the same size as the skinny side of an audio cassette. Other special tools may be needed. Old trick, used in (nearly) every (VW) service station because the results are much better than using the official method with the special tools. Disadvantage: you need a person who helps you. Sit down on the driver seat, your friend has to go under the car. Shift into - 3rd gear for 4 gear cars, - 5th gear for 5 gear cars, have your friend loosen the linkage and adjust the gear stick. Push it (smoothly!) to the right and have your friend link the two parts again. Try to shift into every gear, have a special eye on the rear gear. If you cannot succeed with this method, you can also try to adjust the linkage in 1st gear (of course you have to push to the left side then). Some people find this method easier and more effective than the first one. If you are anxious not to succeed, mark the original position of the linkage parts before losening them. You can then put the linkage into the original position every time. The end of the shift lever has a ball on it that fits into a cup. The cup wears and allows the ball to ride lower and lower. Pretty soon, the ball, with shifter attatched, is riding so low that you don't need to push down to bypass the reverse lock out. All you need to do is replace the ball and cup. While you're in there, replace theshifter bushings for the feedthrough. See the Bentley manual for an excellent description. BTW, you'll most likely have to drop the exhaust to get at the parts. I have done this operation several times on various models, and can honestly say that it can be done in about 2 hours or less if you have a torch to remove the old exhaust clamps. Also check out whether the motor/transmission mounts are ok, misalignment will cause shifting problems as will a dragging clutch. If your shifting effort is hard/stiff on cold days & grinds in 1st & 2nd, but easier once warmed up you may want to change to a synthetic GL4 transmission fluid. Q: First gear grinds? A: Shift into third thirst then shift into first. Q: How can you tell if your synchro is REALLY shot? A: Let the car idle, and with out depressing the clutch move the gear shift into the gears you want to test. If the synchros are more or less ok your idle will dip (or as I found out, your car will start to move) w/o crunching., If however they are shot, you'll hear a big grinding sound. Don't try it with the reverse gear, it has no synchro an will crunch majorly. An alternative is presented by Bill N Gallas: 1) Change the gear oil. If the car has >75K miles on the transmission this could help as the extreme pressure lubricants in the gear oil do wear out. This lubricant failure can manifest itself as syncronizer drag and binding. After changing the gear oil you may notice the problem is gone, :-) life is good! If not: 2) Drive the car for 15 to 20 minutes to get the transmission warm. 3) Accelerate the car to 10 to 40 MPH for gears 1 thru 4. a) engage the gear in question. 4) Leaving the clutch engaged, release the accelerator pedal. 5) If the gear select lever (gear shift) pops out of gear that syncro is bad. 6) On most newer transmissions when first starting out in reverse "ALWAYS" put the shifter into 1st gear, then shift to reverse. By doing this you stop the transmission and will eliminate gear chip damage to your reverse gear.