091 downshift issue

[DPsuper]

I'm running an 091 6 rib in my Baja and going from 4th to 3rd is becoming a problem. From 2nd to 3rd there is no issue at all but 4th to 3rd it acts like it doesn't wana go in there. Any ideas on what needs replaced?

[Henryhoehandle]

3rd/4th slider is probably broke..VERY common problem in these. Also, the 3 synchro keys are most likely bent/broke and may have even fallen out of the hub. The corners break where the keys fit into the slot(s).

[DPsuper]

Is that a Hard fix?

[Henryhoehandle]

Requires complete disassembly...

[Pablo2]

Albins early solution for weak 091 clutch gear (slider hub) :

http://images.thesamba.com/vw/gallery/pix/1144068.jpg

(Unfortunately, this mod requires precision grinding of 091 synchro cones down to 002 size)

[Henryhoehandle]

VW's solution was a rounded slot at the bottom of the slot...and these would break too but were better. Weddle used to require a 002 hub with their hp gears. Now you can just buy a very nice 091 chromoly hub.