This post may contain affiliate links. See Affiliate Disclosure
It was really hard to move the Bus around, because the plastic shifter bushings were worn or missing. The shifter was very sloppy, meaning that with the bushings being broken, worn and missing, you could move the shifter more left and right and forward and backwards and it wasn’t easy to find the gear that you want to get into.
In this episode I will be replacing the shift bushings, rear shift coupler and installing a different shifter.
There may be many different ways to do this, but this is my way.
Starting underneath, the front metal belly pan has to be removed. Next, inside the Bus, make sure the shifter is in neutral, then remove the 2 bolts holing the shifter to the floor, pull the shifter up to remove it, and put a rag or plastic bag around the bottom part that is greasy and dirty. You will see a metal plate on the floor that was under the shifter, put that with the old shifter, as it will not be needed with the new one.
The parts needed are: Shift Bushings, Rear Shift Coupler, Aftermarket Trigger Shifter, grease and some wire.
Ok, next chock one or two of the tires in the back of the bus in the front and back of the tires. This is needed as we will be undoing the parking brake.
Turn the handle inside the Bus to release the parking brake, then go under the front of the Bus. Looking up, you will see where the parking brake is attached and can pivot forwards and back. There are clips on either side of a tubular rod, we need to remove the clip on one side, then tap the pin out. After this is done, the inside the bus, you will then be able to lift the brake lever up. This is needed to be done for the work to be done below.
The shift rod goes from the front of the Bus to the back, but in the middle, there is a square bolt that is a set screw holding the shift rods together, as it’s in two parts. This may be held together by a piece of wire, if there is wire then cut, and remove the set screw. The shift rod can be separated by using two pairs of pliers by twisting in different directions. Then push forward and back until they separate in the middle. You can now remove the front part of the shift rod by moving back towards the middle of the Bus in the space made by moving the parking brake lever.
At this point we might as well move under the middle of the bus towards the back, but in front of the rear tires. I would suggest wearing safety glasses. You will also need a flashlight (this one is my favorite and I use it all the time).
While looking up you will see another square set screw, remove it the same way you removed the front one. Next reach forward and twist the shift rod until it moves forward a few inches away from the coupler.
Now the fun begins… using long locking vise pliers on the side with two metal tabs, and a 8mm ratcheting wrench undo the screw holding the coupler together. Remove the old coupler, and install in reverse order of above with the rear shift rod.
You will notice if you have worked on VW Bus before that I will not be installing the rear shift rod bushings in this episode as they still were working.
Ok, let’s go under the front of the Bus again. When you pulled the front shift rod forward, you might have pulled it out of a plastic bushing in a round hole. Well, mine was missing and that is one of the main reasons for the slop in the shifter. in the new shifter bushings package, you will find a new bushing with a split in it that fits in the bracket. After it is installed fill the inside of it with the grease.
Next make sure the front shift rod is clean of the old grease in the hole where the shifter goes and around the shift rod itself. Before reinstalling the shift rod, put a few fingers worth of grease in the hole where the shifter will go.
Reinstall the front shifter with the set screw. Now cut 2 pieces of wire and use one in each of the two set screws (if there is a hole in the set screw when you removed it) and go around the shift rod, then use the locking pliers, twist the wire until it’s in a tight braid, and tuck the excess away on the side.
Put the parking brake level back together again and put the metal belly pan back up.
Finally, inside the Bus install the new trigger shifter with the new hardware. You might have to loosen the shifter and wiggle it a little forward or backwards to line everything up. But all the work was worth it. The shifter isn’t sloppy, and you don’t have to push down to get into reverse, because now you lift the front trigger ring with your index finger. As a bonus, this is a short throw shifter meaning that you don’t have to move it forward or backwards as much to shift it.
Hope you enjoyed this repair entry.
Leave a Reply