Another 915 Shifting Problem

[rraynman]

I have read so many 915 shifting and rebuild related posts trying to figure out my problem and I am still unsure.

My problem is that with the car parked and engine off it takes a lot of effort to shift into 2nd, 3rd and 4th. The problem is also evident while driving and makes driving very laborsome.

I went by a couple of dealerships, with cars similar to mine (85 Carrera), and I am able to select any gear with very little effort. Each gear clicks very nicely where as on my car there is more of a thump.

I have adjusted the shift coupler and replaced all the bushings. During one of my many coupler adjusting attemps I tried selecting gears by moving only the coupler with the shifter disconnecting and the problem still exists, meaning I can select 1st with minimal effort but 2nd, 3rd and 4th and very difficult.

I checked the shift guide fork and it was tight. Swepco is going in next, but somehow I don't think it will make that much difference.

From the previous posts I have read about dog teeth becoming rounded causing the gears to jam up, sliders not sliding and bent shifter forks.

Has anyone had this sort of problem? Is a rebuild the solution?

Thanks,
Rob.