A 1978 VW Bus recently developed a problem downshifting into second gear after an engine replacement. Although the transmission and shifting mechanism weren’t touched during the install, the issue surfaced during the test drive home. The bus shifts smoothly into all other gears, both up and down.
Initial troubleshooting steps included inspecting and refreshing the shift rods, replacing the shift coupler with a genuine German OEM part, and cleaning and lubricating the front shift rod bushings with molybdenum disulfide grease. The original O-ring bushing and shift rod bushings were in good condition and were reused. The gear shift lever and shift rod cup were also cleaned and re-lubricated.
Despite multiple reinstallations and adjustments following Bentley and Haynes manuals, the problem persists. Second gear engages easily with the engine off, and all gears upshift without issue. Downshifting into third gear works perfectly, but second gear remains inaccessible while driving, regardless of speed. Removing the quick shift plate doesn’t resolve the problem either.
The primary question is whether further adjustment of the shift linkage is likely to solve the problem, or if the issue points to an internal transmission fault. Are there specific adjustment techniques or potential pitfalls to consider? Could the engine replacement, despite not directly involving the transmission, have indirectly contributed to this issue?
Experienced VW Bus mechanics or enthusiasts might have encountered similar situations. Insights into diagnosing and resolving this second gear downshift problem on a 1978 VW Bus would be greatly appreciated. Potential causes, recommended diagnostic procedures, and possible solutions are all valuable information. Understanding whether this issue warrants professional transmission repair or can be addressed with further adjustments is crucial.
