Gear problem in France

[Evokiola]

Hi all. Have had a great time trippping around but I've got a problem. I am in montrieul sur mer nr Calais and I have a 88 4speed dg. Gearbox no 09130110302.
From my research this is the case: the joint at the ball lever that goes onto the shift rod and sits inside shift lever covered by a boot. The nylon? ball end comes out of the lever on the side of the gearbox when I change gear. I only have first.
The Haynes shows a 5 speed lever as a hook shape, which is the one on mine with 2washers.
The Bentley shows lever without a hook.
I have no constant Internet connection so am a bit stuck. I was hoping someone would be kind enough to offer some advice as I am unsure what to order, also if there is anything else to check. I will hopefully get a brickwerks delivery but I sail back on saturday so am possibly up against it. Thanks in advance

[Evokiola]

From further investigation it seems the splines off the gearbox and lever are worn. Does anyone know of a temporary fix for this whilst I await the part. Many thanks.

[Aidan]

the get you home in an emergency solution is weld it but you need to not break off the threaded end so don't go mad with tightening the m8 nylock nut and there should be a nice thick washer under the nut not massive diameter but double thickness
when you mate the cup and ball ensure cup is fully up before locking off the two m8 bolts holding the rear bush plate to the box and clean out any crud from the cup and add some clean lube before mating, if the boot is split replace it when back home
the replacement ones tend to be a tighter fit on a worn shaft

[Evokiola]

Hi Aidan, thanks for the reply. Just what i wanted to hear.
I was wondering yesterday about welding or possibly wrapping thin copper strand criss crossing the splines on the m8 side to get some purchase. Obviously if a weld is needed it will be essential to be in the right position. Would you weld after putting the whole assembly together?
Brickwerks are delivering to me the lever and boot so hopefully that will mean I make my crossing. I will post again when I get home. We have had a great first European road trip through Belgium, holland and into France and love campervan life...and I am enjoying learning as I go. But that's for another time. Thanks again mate.

[Aidan]

hopefully you won't have to weld, the new one may be tight enough to do the job, weld is get me home emergency solution
If you weld the shaft is scrap and will have to be replaced if box needs a rebuild and too much heat can melt the seal

[Evokiola]

Well that seems to have worked without welding being necessary, quite a simple operation really, Boot on the ball,greased the ball and cup used 2 washers behind the m8 nut. I had ordered a new boot too.
The gears now seem a lot closer together ie very sloppy previously, however being a van virgin i possibly didnt know what sloppy felt like. When i bought the van 2nd was hard to find. Im thinking this was the wear on the splines.Upon fitting the new part I thought I had no 2nd gear at all. I do have 2nd its just maybe closer/tighter than the sloppiness before.
Thanks again Aidan for your input. Fingers crossed for the trip home

[waltraud]

Good luck, difficult when ur abroad bu im sure youll make it, we did n a tricky situatiln.

[Evokiola]

thanks mate, glad to read you made it, we also made it safe and sound, our Gordon did us proud.

[dearjohn]

Mine is doing the same thing, but the splines on the shift lever are fine. Plastic/nylon ball comes out of the Cup arrangement if reverse selected. Then under with 2 13mm spanners and drop the rod as far as it will go and get the ball back in place. Gear Lever seems to get "jammed" in the reverse position. (1.9 petrol, 5 speed) Have made it from Roskoff to Cherbourg and all around, so far with only 2 occurrences, but not using reverse. Feels like problem is up front under the gear lever, too much travel perhaps? Boat tomorrow, so should make it home OK. More maintenance needed!

[Evokiola]

hi dearjohn
with mine it took a little while to realise that the 2 sets of splines were not locking and moving in unison. When i offered up the old part it seemed to fit on and it did rotate the shaft and change the gears. It was only third time round the gear linkage system, rod dropped and with good light did i see the slip of the lever that would cause the ball to come out. I did what you did placing the lever ball back in, managed to get into first only, maybe mine was further gone than yours, and i probably finished it off driving for 20 mins on cobbled lanes. I will say that up the front end on mine everything looked and felt pretty good, no odd movement around the base of the gearstick as far as i could feel.
When i replaced the lever it has drastically reduced the amount of travel in the gear stick when changing gears.
main roads=fewer gear changes, avoid cobbles, and no reversing should be needed on the boat
all the best, bon voyage

[dearjohn]

Watched a "Celtic Link" ferry unloading, and they had the campers on the top open deck, drivers had to reverse round the centre island and then drive off. Was wondering how they would respond if I had to hold up proceedings and dive underneath! Good news it, made it to the boat no problem. 17 hours and we will be back on dry land, then 200 miles and home. So will manage that OK! Get it up on a bit of a ramp and probably then ring Brickwerks !!!!

Character building, is what it is

[Evokiola]

Character building it is. The journey is definitely half the fun and more
have a safe trip