mk2 with aaz not going into 2nd and 4th very well

[trent77]

So I put my engine in about 3.5 years ago. When I did I installed new bushings and levers in the shift linkage. Everything was great until recently when I go for 2nd or 4th and let the clutch out I grinds a bit, and is not really in gear. I can usually find both gears with a little work, but it takes a couple of tries. So I got underneath and checked over everything, also ordered and used the VW special tool for aligning the shifter, lubed everything and I still happens. The only thing that is adjustable is the clamp bolt on the selector shaft, I'm at a loss. Any help would be great, I have been standing over it for a couple of days off and on. Thanks
Trent

[trent77]

Also, I just changed the gear lube today. I'm trying everything that I can think of, other than getting new parts only to find out that I have the same problem. Next step is going to be "missinglinkz"

[Dakotakid]

The VW tool is well and good, although, it does not control the amount of shift rod shaft (the other issue/source of adjustability) in relation to the clamp (the circular clamping for at the most forward aspect of the shaft.
 
My rule of thumb here is to ALWAYS either measure, mark, or at least pay attention to how much shaft was protruding "forward" of the clamp before disassembly. A lot of times, there will be a sort of line of "demarkation" where the shaft was "clean" under the clamp and where all the engine oil drippage and dirt soil and darken the shaft (where the shaft was exposed prior to disassembly).

Generally when I put one of these back together or assemble a car from scratch.....this is only a guess....there is like 3/4 of an inch or so protruding forward of the clamp. This would be a good place to start. Because, I think THIS is YOUR problem.

You've got to start the WHOLE process by loosening the clamp to take all clamping force off the shaft and then (from under the hood of the car) reach in with your arm and hand and "zero-out" the under hood shifting linkage to the best guess of "center of neutral.".....and start the process from there. And, yes, have the special VW tool in place at that time.

I can't do a better job explaining than what I have done. It is a common-sensicle sort of process best comtemplated with a warm beer and a half-eaten hotdog in your hand........

[the caveman]

check the bolt at the top of the linkage where it comes out from the center of the car. also make sure the short hockey stick on the bottom still has the ball on it. that part of the linkage doesn't have an adjustment, all it does is move the rod in/out of the trans. Your problem is because it's not throwing far enough