If you cant get it into gear at the gearbox nose, messing with the shifter is a waste of time, if you take the gearstick out completely, the gearbox should offer all 4 gears and reverse by manual operation of the coupler. Jack up one rear wheel then you can turn the pulley at the back of the engine with a spanner and safely see and feel the quality of gear engagement by turning the nut or turning the wheel against the gearbox. You are pointing more and more to something inside the gearbox has gone adrift. Hopefully the donut as you can check that by taking the engine out then the gearbox, take the nose off with the gearbox standing on the bell housing so most of the oil drains back first. I managed to preserve the gasket when I took the nosecone off my gearbox. Also the bracket inside the nose of the gearbox that holds a rod that is a crucial part of the shifter mechanism has been known to break. It can be welded. Then if you still cant find the gears, its off to a gearbox expert hopefully all it needs is adjustment of the shifter fork inside.
Well guys after locking myself in a dark room and giving myself a good talking to I am ready to admit defeat.....I thank you all for you input and help but now it’s time to send out an S.O.S to see if anybody has a fresh pair of eyes I could borrow I would be very grateful if someone is local to me and could spare an hour or so to show me the error of my ways, I’m located in Selby, North Yorkshire....fingers crossed Someone can answer my call.
Accidentally moving the selector fork. It's possible. If you prised hard against the end of the selector shaft in the gearbox while in 1st, say trying to squeeze the rear coupling in it can happen, theoretically. I have heard of this happening to 3rd/ 4th (IIRC) when a box is being transported loose in the back of a van, brakes applied, box slides into the partition selector shaft first. It does seem very unlikely though.
I think I'd agree with Mike, if 1st is really stubborn. As above, work the box by hand if you can get a firm grip on the "cup" (better doing it at the back end, but with the Y-tube in the way, difficult). Don't forget everything works "backwards" under the floor. Hopefully, you'll find first. If not, it's likely the selector end. Easy to take the nosecone off to have a looksee, but that does involve taking the engine and transmission out
While not recommending it in any way, there are people who put an inspection plug in to access the first/second gear selector fork lock nut e.g. E.g. At about 2:00 But my guess is you have a gear box needing this. Worn donut on left, new on right .because the end of the selector shaft (aka hockey stick because it is shaped like one) waggles around uselessly and hits the side of the internal shift lever instead of moving it to engage gears- the bevel inside the hole in the end is metal to metal collision the donut fits in that hole over the end of the selector shaft on the other end of which goes the shift coupler outside the gearbox.. It cost about £3.50 at the time and engine out and everything. Its a lot of bolts and dont forget to take the external shift coupler off or you can bend the hockey stick or crack the gearbox nose cone as you try to lever the rear suspension tube off the bus with the gear shift assembly..
Thanks once again for the info mike, unfortunately the images of the donut and it’s position haven’t or won’t open up, could you email me them across so I know what I am looking at please email address is davesouthwell1960@gmail.com Thanks
Don't panic just yet. Get under, leave it all connected. Try and get first by hand then check by starting with it still in gear. Any amount of messing about is easier than engine/gearbox out. I would want to be 100% sure I'd proved it's not a linkage problem first.
@Flyer60 , going back to your original post, you said the van was running like a dream, but you needed to change out the clutch, why was that? and when you put it all back you replaced gear linkage bushes etc. You had no issues with gear changing before you did the clutch replacement, so maybe its something more to do with that, like clutch adjustment?
Really give it a good wiggle, from the gearbox nose cone . Good positive clunks and positive selection should be your expectation.
Once it has stopped raining I plan to give this a go, bit too wet at the moment for laying on the ground under the old bus.
That’s correct until the clutch bearing decided to give up the ghost, gear selection had never been an issue with the empi shifter fitted
I can remember for some stupid reason bogging down in the boggy T5 trap bit on the grass at Sandown park just by TLB traditional camping spot, having just enough room to reach under and force it out of gear from the gearbox coupler because there was not quite enough movement on the gearstick to do it from the front.. and my gearbox is not in 100% prime condition..
Afraid not weather has put a dampener on this to say the least, unfortunately the van is not undercover and the area where she sits is now well deep in water so I need this rain to stop and the sun to come out again before I can continue the hunt for the elusive 1st gear......I will keep you posted
