Overhauling 5 speed gearbox linkage

[Smiffo]

I'm going to have to take the plunge on this I think and make a decision.
Weigh up my options...

I either buy all the extra bits new to go with my gearstick ( locking pin, ballbearing, circlips and rubber selas etc then order that spring in your link ), or just get a second hand LHD one and take the bits I want before selling whats left.... ( Far cheaper than RHD and probably not as rare. )
I will add a wanted add I think, and wait a few days to see what responses I get before deciding ultimately.

Thanks for the Link SB, I may well end up being the guinee pig on this one.

[silverbullet]

Just remembered that there should be a small rectangular section rubber ring at the bottom of the detent groove in the plunger, I guess its there to try and quieten the "snap" of the ball?
Only ever seen rotten/snapped ones but I have only repaired a few levers.

[Smiffo]

Just remembered that there should be a small rectangular section rubber ring at the bottom of the detent groove in the plunger, I guess its there to try and quieten the "snap" of the ball?
Only ever seen rotten/snapped ones but I have only repaired a few levers.

Yep, I think it's this bit I found before while searching around...

https://www.brickwerks.co.uk/index.php/ ... -bolt.html" onclick="window.open(this.href);return false;

It's been sat in my `boot` waiting to order, but need to know which direction I go in LOL.
I will wait a few days for responses in wanted section first.
If no joy, I will take a punt on the Brickwerks bits and a spring from your link.

[booted]

I am soon going to replace my 5 speed box with a 4 speed DK box.
I believe i can use a later 4 speed stick and forward linkage.
If this is the case i wouild be happy to swap my 5sp bits for your 4 speed bits
just need to establish whats neded to get the DK to work

[Smiffo]

I am soon going to replace my 5 speed box with a 4 speed DK box.
I believe i can use a later 4 speed stick and forward linkage.
If this is the case i wouild be happy to swap my 5sp bits for your 4 speed bits
just need to establish whats neded to get the DK to work

Spot on, Booted.
Send me a PM with timescales etc - my 4sp stick is the 14mm variety. I assume that is the later one you mean.

[Smiffo]

Just remembered that there should be a small rectangular section rubber ring at the bottom of the detent groove in the plunger, I guess its there to try and quieten the "snap" of the ball?
Only ever seen rotten/snapped ones but I have only repaired a few levers.

Right - after a bit of a delay here, and some too-ing and fro-ing, I have placed my order for everything now.
Just waiting for Lee Springs to call me for my spring order ( Apparently for private orders and anything under 5, you have to call and send an email. )

I will keep you updated - thanks for your direction on this SB.

[Smiffo]

Bits turned up yesterday - including the spring from Lee Springs..!!

All seemed to go together easily, and here is my 5sp stick with indent mechanism:



Now all I need is some time to take the old out, and put the new in....

Thanks for the pointer on the spring SB.
Worked a treat so far

[booted]

I am soon going to replace my 5 speed box with a 4 speed DK box.
I believe i can use a later 4 speed stick and forward linkage.
If this is the case i wouild be happy to swap my 5sp bits for your 4 speed bits
just need to establish whats neded to get the DK to work

Spot on, Booted.
Send me a PM with timescales etc - my 4sp stick is the 14mm variety. I assume that is the later one you mean.

sorry for not replying sooner im not getting notifications for some reason
due to be done in january

[Smiffo]

Update.

Ok, today I made a start on this, but came up against an obstacle.
I can't get the pin out in the pics below:





The OP of this thread mentions using suitable `drift` and driving out into the cup from the outside.
What is meant by suitable `drift?`

Does he just mean put a small screw driver into it and hammer the bugger..!!??

[Plasticman]

easy now you have it off, use a punch of a diameter just smaller thatn the pin and it will easy tap into the cup end.
even a masonry nail but whatever dont use a sharp poinnt or a screwdriver as the roll pin is hollow and you will feck things up
mm

[Smiffo]

easy now you have it off, use a punch of a diameter just smaller thatn the pin and it will easy tap into the cup end.
even a masonry nail but whatever dont use a sharp poinnt or a screwdriver as the roll pin is hollow and you will feck things up
mm

Thanks Metal Micky.

I got the pin out using a bolt to place over the end, and a few taps of the hammer, but the whole end seems to be totally seized on.
Even with the roll pin out, the end won't budge...

I've given it a few blows with the hammer but don't want to damage the shaft.
( Not worried about the cup bit - I have another one to go on. )

Would a bit of heat help?

[boatbuilder]

Maybe put something hollow and round over the end of the shaft and whack it in the opposite direction first to free it up.

[itchyfeet]

Maybe put something hollow and round over the end of the shaft and whack it in the opposite direction first to free it up.

^^^ exactly that as seen on this wiki post , a socket will do...
http://wiki.club8090.co.uk/index.php/Ge ... hanism_Pt3" onclick="window.open(this.href);return false;

[Smiffo]

Cheers all.

I will give this tactic a go later..!!

Appreciate all the pointers here - you've all saved me time and stress.

[Smiffo]

Update...

Well, all was looking good - managed to get the old cup off, changed the rear bush - you can see the old against the new below:



Got the new cup, bushing and `gaitors` on the rear linkage:



Trust me, without a vice that was hard work..!!

I had a grand total of 1minute to be thoroughly pleased with myself before it dawned on me.....
This bit was still on the floor:



Noooo...!!

Never mind I think, perhaps I can wriggle it on the other end while I do the plastic and rubber seals there:





Alas no - it isn't meant to be - it will fit over the shaft, but not the bush bit the other end...
So here I am, kicking myself for being such a muppet...
I'm having a coffee before I launch Boyd and his wonky linkage into the river Severn..!!

I'm not going to attempt getting that cup off again without a vice this time.
A trip to a kind relative with an adequately equipped workshop is now penciled in for tonight.

Moral of the story - if you are determined to make mistakes - guess how long something will take, and triple it to be safe..!!
Better still, pull a number out of your a*** as it will probably have just as much chance of being accurate