Wrote my post about the gearbox rebuild too early. Here is the summary:
All went well after the box went back in. Drove the van around Port Mac for a month with no issues. Then went on a road trip via the South Coast to Melbourne. First 400 KM to Sydney, no worries. Then around the Coast, Berri, Kiama and down to Culburra Beach. Then down to Eden. All good. A happy VW owner at the wheel. At this stage the new box had done about 1000 kms. Then on the way from Eden to Lakes Entrance it suddenly pops out of 4th gear. Does it again and again. I go into third and then back into 4th often. Got into Melbourne after it happened again a few times and I kept holding it in 4th. My left arm has strong muscles as a result!!
A week idle for the van while I flew to Hobart, then drove back from Melb to Queanbeyan. Took note that it was more prevalent when first being used and then less likely to come out when everything warmed up. On 19 Jan drove from Queanbeyan to Port Mac. Left it alone and it jumped out once early on. After holding it for a few KMs I let go and we drove all the way home to Port Mac and it did not jump out once!!!
Have just spent 3 hours with our local expert VW mechanic friend trying to adjust the linkage in case that was the issue. Adjusting at the spline in the middle of the drive train. What fun. It kept jumping out and then he must have gone to far because after about 30 adjustments to and fro we now have reverse, 3rd and 4th but no 1st or second. I am so fearful that the the issue is the box and we have to take it out again.
I have trawled the various VW web sites for days and many others have had the same problem, particularly after a rebuild but I am yet to find a solution.
We will try again tomorrow afternoon to get all gears working. If not, despair!!!
Our tactics are to get everything right and eliminate other possibilities and if it still happens then its the gearbox. After all, why did it suddenly start to happen?? One issue is that the rear bellows appears to be overly compressed in 4th. But 2nd is rock solid and nothing we can do makes it pop out of second
Sorry to post such a negative story but it has been a long day under the van!!!!!
Peter from Port