Hard Shifting into 2nd Gear

[pdub]

Hi

I have a 2276 mated to a Rancho trans. Its an IRS trans ('69 Baja bug), with Kennedy 1700# PP and one of those non sprung disks...ones with 'easy engagement'. Any way clutch tube has bend, clutch pedal free play is about 1.5". It shifts pretty easily into 1, 3, 4 and reverse but in second I always get a hard shift or even a bit of a grind. Seems to be worse when cold. It did this to some extent even right after I installed it a couple-few years ago. I replaced shift rod coupling, rubber coupling at end of rod, adjusted shifter every way from Sunday. I'm thinking it is not clutch or clutch drag or it would do it in other gears as well, right? Same with linkage, if it were somehow whacked wouldn't it affect other gears as well?

It does seem to shift best when I shift at low RPMs. But oddly sometimes it shifts smooth when Im accelerating hard. It shifts worst at "normal" speeds/RPMs!?

Any Ideas? Just a bogus trans with a shitty 2nd gear synchro?

[mcmscott]

I like self diag, especially correct self diag
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68 Ghia
67 T-1
65 Notch
02 Mexican beetle
74 Thing
15 Long travel rail
07 Nomad
05 f-250

[sgmalt46]

its the trans call them if it's only one gear it's the trans
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55 deluxe 23 window bus
64 crew cab
55 rag top beetle
66 beetle
71 square back (sold) ! good luck with it Henry!
46 beetle 552nd royal army service corps CCG

[pdub]

Dang it! I guess I sort of knew it but was hoping it was maybe something more simple.

[thomas.]

What about this shifter bushing. Has it been changed. mine was grinding downshifting into 2nd only and this fixed it.
http://www.wolfsburgwest.com/cart/DetailsList.cfm?ID=111701259A

[Bruce]

[mark tucker]

dam those new syncros I agree if your taging reverse....it's an issue and....needs fixed. I opened up the shiter mounting holes to about 3/4 square and use good hard fender washers to hold it where it get it adjusted to where I want it.

[Multi69s]

Just for giggles, check you motor mounts, trans could have shifted.
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69 road Bug 2110
73 Squareback - 2L, T4, Automatic W/ AC
Gone, but many fond memories 69 Baja Bug 2010 - 5 Rib Bus Transaxle
Gone but not forgotten 72 Baja Bug 2010
My builds
T4 into Squareback http://www.thesamba.com/vw/forum/viewtopic.php?t=458944&highlight=
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AC in Squareback https://www.thesamba.com/vw/forum/viewtopic.php?t=...highlight=

[pdub]

Thanks for ideas on nicking reverse gear. I'll try drilling the shifter holes larger to give me more shifter adjustment room. I have tried several adjustments but none successful thus far.

Mounts are all CB Rhino mounts plus I have trans strap in front and reinforcment bars bolted to rear motor mount saddle that are tied into roll cage. No clunking around or chattering so Im pretty sure that isnt it.

[Howard 111]

You have way too much free play. Did you replace the old cable? Was it the correct length? If using the old cable, it may be unraveling and gets longer as it does until it breaks. Don't pull that trans until you have checked all the simple fixes.
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1973 Karmann Ghia
Turbocharged, Fuel Injected
http://www.thesamba.com/vw/forum/viewtopic.php?t=531270

[pdub]

1.5" of pedal free play is way too much? I think the old Manual says 1". Ill tighten it up a half inch. What is the textbook setting? Cable isn't that old and adjustment has not been changing so I don't think the cable is fraying.

Appreciate the ideas. I really don't want to pull the trans

[Howard 111]

Free play should be 3/8 to 1/2. Using your hand, this should be the amount of distance the pedal will move down before you feel any resistance. Getting it right can make a world of difference.
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1973 Karmann Ghia
Turbocharged, Fuel Injected
http://www.thesamba.com/vw/forum/viewtopic.php?t=531270

[smkn_vw]

x2. 1/2" and shifter adjust and you're good as gold.
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