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    Thread: 1992 mk1 keeps losing cotter pin on shifter rod

    1. Member
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      1992 Cabriolet Wolfsburg ed
      05-16-2012 01:42 PM #1
      About a week after I got my cabby the cotter pin broke and stuck me in 2nd. 2100 miles later the new one I put on broke leaving me in 3rd or 4th gear. Luckily I had a paper clip in the car and made it home to put on another cotter pin. Are bad bushings causing this?

    2. Member CajunSpike's Avatar
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      05-16-2012 02:01 PM #2
      Its possible. If the bushings are so bad that the rods come out of place/alignment, that could put so much force on the rod when you shift, that it kills the pins.

      I had the same issue on one car I revived. the linkage kept popping out of place, pins or not.
      wasn't until I replaced the bushings that it behaved.

      You could perhaps put a thin washer between the bushing and the cotter pin..see if that helps keep them separate and to spread the load.

    3. Member
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      1992 Cabriolet Wolfsburg ed
      05-16-2012 05:27 PM #3
      Will replacing the bushing on the shifter rod improve going into 5th? Or are there other bushings that need replacing to fix that? I can get into 5th but the car prefers to go into 3rd before 5th.

    4. Member CajunSpike's Avatar
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      91 Burgundy Etienne(2), 06 Jetta 2.5, 08 GTI 2.0T FSI
      05-16-2012 05:41 PM #4
      Get a shift rebuild kit with all the parts like the second one on this page.
      You won't regret it.
      One of my cars, it was hell to consistently get it into any gear.
      After the rebuild kit, gears are where they are supposed to be and the motion is slick like butter.

      http://www.germanautoparts.com/Volks...smission/186/1

      The bushing on the shifter rod is not included...I found mine on ebay.

    5. Member briano1234's Avatar
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      05-16-2012 05:42 PM #5
      Sound like you need to rebuild all the the bushings and replace the linkages. Including the main delron one on the shaft. Then replace the transmission mounts and adjust the linkages and you should be good to go.
      Grounds, Grounds, Grounds Replace them things.
      Divorces, Great Coffee, and Electrics, all start with GOOD Grounds.

      Another Useless Ground Thread
      HAVE YOU CHECKED THE FAQ's ABOVE..PAGE 3 Thread 75? Why bother no one else does.
      You can lead a user to a link, but you can't make them click.

    6. Member
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      05-16-2012 05:46 PM #6
      Awesome! That's much easier than chasing one at a time.

      This car was babied in some areas but certain things were totally missed. Like new radiator and water pump (by previous owner) but he left all original hoses. Boy was that a mess!

    7. Member tolusina's Avatar
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      05-16-2012 05:47 PM #7
      This kit......
      http://www.germanautoparts.com/productdisplay/2269
      has all the ESSENTIAL bits.

      This assembly.....
      http://www.germanautoparts.com/productdisplay/2209
      is sometimes needed.
      Quote Originally Posted by kamzcab86
      I hate reading: "But I bought this car for $500 and don't want to put another dime into it."
      ____(hey, it's VW AND it's electrical, what's not to fail?) neoBentley+



    8. Member
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      1992 Cabriolet Wolfsburg ed
      05-16-2012 06:05 PM #8
      Will the bushing replacement correct my reverse lockout not working or is that another part to add to my list? I don't have to push down to engage reverse so there is no resistance when going for first and hitting reverse instead.

    9. Member briano1234's Avatar
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      05-16-2012 08:14 PM #9
      Reverse lock out is in this:


      Linkage kit with bushings are be sure to order the set for your tranny 4 or 5spd:


      how it all goes together.
      Grounds, Grounds, Grounds Replace them things.
      Divorces, Great Coffee, and Electrics, all start with GOOD Grounds.

      Another Useless Ground Thread
      HAVE YOU CHECKED THE FAQ's ABOVE..PAGE 3 Thread 75? Why bother no one else does.
      You can lead a user to a link, but you can't make them click.

    10. Member tolusina's Avatar
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      05-16-2012 09:33 PM #10
      Quote Originally Posted by briano1234 View Post
      Reverse lock out is in this:

      Well, sort of. When that ^ fails, reverse lock out no longer locks out, but that ^ isn't really the lock out at all.

      The lever is held up by the spring shown just under the circlip in the pic below, when the plastic ball/socket affair shown above fails, the lever drops down.

      ---

      Reverse lock out is actually at the very bottom of the lever as shown in the pic below.
      When the lever is pushed down, compressing the spring shown above, the hook shaped part to the right (in the pic) of dimension 'a' drops down below the lip of the bracket to the left of dimension 'a'
      allowing the bottom of the lever to move farther left (in the pic) to engage reverse.

      ---

      Right and left are all backwards between the description above and the car as the pics above are viewing the parts from the front to the back.
      Left and right on a car are always as viewed from the driving position, so, what is on the right in the pics is on the left of the car.

      If that isn't confusing enough, the bottom of the lever moves in the opposite direction relative to the shift knob due to the pivot near the bottom of the lever. When the shift knob moves left to engage reverse, the bottom of the lever goes right.
      ---
      I'm getting a headache now, I'ma stop for a while.................







      .
      Quote Originally Posted by kamzcab86
      I hate reading: "But I bought this car for $500 and don't want to put another dime into it."
      ____(hey, it's VW AND it's electrical, what's not to fail?) neoBentley+



    11. Member
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      1965 Beetle, 1987 Triple White, 1988 cabriolet, 1993 2dr Fox gl, 1999 Jetta GL
      05-17-2012 08:29 AM #11
      If it were mine I'd replace the Derlin bushing on the shift rod 1st...... then you can see what other adjustments you need to make. Not your issue but I can't keep relay lever bushings in my 88' for longer than 7-8 months so I did like I've done on every MKI GTI I've ever had and made bronze bushings and put them in the relay lever bracket..... old poly/plastic bushings on the right, bronze on the left.

    12. Member
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      1992 Cabriolet Wolfsburg ed
      05-17-2012 01:10 PM #12
      Ok so I'll start with the bushings kit. It looks like if I need to replace the second part then I should probably change out the entire assembly. I'm sure more than one part is worn in the shifting assembly.

      You guys are so helpful!

    13. Member
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      1965 Beetle, 1987 Triple White, 1988 cabriolet, 1993 2dr Fox gl, 1999 Jetta GL
      05-17-2012 01:44 PM #13
      Look at the "relay lever" (at the bottom of the relay shaft...black rubber ball a.k.a "the golf club") in Brianos shifter linkage assembly and see if your ball has flat spots on the sides...if so I'd replace that too.

    14. Member
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      1992 Cabriolet Wolfsburg ed
      05-23-2012 11:35 PM #14
      Digging around today checking out the current cotter pin I bumped into the bottom air hose (goes to exhaust?) and noticed the sloppy linkage had caused the shifting lever to pop a hole right through it.

      Guess I know now why I kept smelling exhaust. I thought that was part of driving a convertible.

    15. Member CajunSpike's Avatar
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      05-23-2012 11:47 PM #15
      If the hose you're talking about is a soft whiteish colored hose that runs from the exhaust manifold to the airbox..its called a pre-heat hose. it warms up the air for real cold mornings. there is no exhaust gas in it....just exhaust heat, unless your exhaust gaskets are gone.

    16. Member
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      05-24-2012 12:19 AM #16
      Well that is good and means the fouled plug I replaced was causing that stink instead and I don't really need to worry about that hole right now. I bet that fouled plug is what blew the hole in my air intake hose. I wonder if anyone has ever mentioned that these cars are like a waterfall.

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