Mine felt pretty tight when shifting for 1500, 2000 miles or so after it was gone through. I'd change the oil about that mileage after a rebuild, and strain it.

As others said, it could be that the coupler needs to be adjusted, or something else is wrong.

However, I also remember reading somewhere (can't find it now, but very likely this forum) that the 915 has a baulking mechanism that prevents the gear being engaged before the speeds have synchronized properly (e.g. to let the brake bands/synchos do their work).

So I think you're working against that if you rush the 1st-2nd shift, especially if changing up at low RPM - e.g. below 3,000 RPM, like in traffic.

My '86 915 has always dropped straight in 1st->2nd if I rev to 3,500 or above, the shift takes longer otherwise - and both 915's I've used in my car have behaved exactly the same way.

I believe this is Working As Designed, you can't beat the mechanism, so don't try; it'll let you know when it's done and slip straight into gear.

Contrary to widely-held belief, a 915 with good dog gears, synchros and brake bands doesn't require you to double-declutch in order to select 1st above 20 MPH - but I happen to know what those wear items cost nowadays, so I prefer to do the work for them.. :)

The switch is $130, you have to take the wheel and housing covers off, replace the stalk, I seem to recall a couple of flying connectors and a bulkhead plug, then re-assemble. About an hour if you've never done it before and being careful.

If you didn't own any of the tools, you could buy them for less than the labor rate - and then you'd have them for the next minor job... I happily pay my independent shop for things I don't feel comfortable doing myself, or don't have the tools/equipment for. Turn stalk is DIY in my book.

Great info on the bushings.. I was doing a search and this thread came up, thanks for the link to the article. Mine is doing the same thing. Doesn't have a hard time going into gear (ie. doesn't grind) but sort of pops into place. I figured it may be a shifter/bushing issue because my 914 did the same thing till I sorted through all the bushings on the linkage.

Great thread!