Gear shift rod repair kit

[silverbullet]

Blatant plug warning!
Here's something that I am testing before releasing to you good people (spot the difference!)

Most of the damage to the original nylon tips seems to be due to degredation of the nylon due to exposure to oil-based grease, causing it to soften and then tear/fracture at age-related cracks in the mouldings.
Once I'm happy with the durability of the repair and there are some clear instructions for installation, they will be available as a DIY kit.
You will need to remove the lever from the vehicle but fitting is genuinely easy (you don't need any special tools, not even a bench vice) but you will need to allow setting time for the epoxy that is necessary to "pot" the repairs firmly onto the tips before fitting. Strip out 20 mins, degrease and glue the same, leave overnight and fit in the morning. Faff about for an hour to get the shift right and then
Needless to say, the difference in shift quality is remarkable! I also applied some bitumen sound deadening pad offcuts to the gate box, it nearly stops the clanging and clonking, much more refined.
I'm also using Rocol MX22 silicone grease as an alternative as it doesn't attack plastic or rubber and has no solvent so won't wash off. Should be good on the lever ball as a replacement for polygrease too.
These kits will obviously fit 4-speed levers as well, 5-speed kit now in development and will be tested very soon.

Thanks to Aidan for the dimesions, loan of the spare shift rod for testing and for reminding me repeatedly to get on and develop this original concept

[jebiga41]

very nice and just on time was looking at mine on the van the other day and need fixing put us down for two sets when they are ready thaks Ian

[lhd]

Top job there mate and as said in the previous post, just in time.
Rob.

[sonic23]

Good work that man. Put me down for a set please. Rich

[toomanytoys]

[Titus A Duxass]

I'll be up for a 5 speed jobbie when one's available.

[KINGPRAWN]

cash ready....just say when please

[silverbullet]

Just finishing the first 2 pairs of prototype 5 speed lever tips this morning. I have a badly bent lever to do a trial fitting, which will also be the recipient of a "Repair kit, gear lever, field fit" MK1*
I'll then put the other pair on a bus for durability tests (need an MOT for that one...tyre swapping time!)

*minimum tools required: molegrips, hacksaw and hammer plus spanners to remove and refit, but doeable at the roadside. That's the concept anyway.

[silverbullet]

Has anyone got any clear pictures of snapped off gearlevers? Early or late, 4 or 5-speed, just state the vehicle in question.
I'm trying to get a feel for where they typically snap so the repair kits (12 and 14mm) can accommodate the full range of unpleasantness and get 100% of folks back on the road ok.

[Aidan]

generally they snap where the grub screw in the collar is fitted - grub screw causes stress raiser in crap metal, should have drilled the seats better, not sure they were even drilled in production but last one I had off VW did have a depression, maybe stamped rather than drilled, before passivating

if you fit a short shift kit they may snap where the collar used to be once it is relocated by 10mm and the fulcrum point moves

4 speed sticks available in solid now from Baxter, 5 speeds you need to tap them and fit a threaded insert, weld and grind to make a suitable repair

[silverbullet]

I'm thinking along the lines of a low-cost "keep it in the glovebox" item that could be fitted with minimal tools/skills for owners to continue their journey/holiday, then repair or replace properly once safely back home.
If they only cost a fiver or thereabouts there would be no excuse not to eh?

[jebiga41]

I'm thinking along the lines of a low-cost "keep it in the glovebox" item that could be fitted with minimal tools/skills for owners to continue their journey/holiday, then repair or replace properly once safely back home.
If they only cost a fiver or thereabouts there would be no excuse not to eh?

Way ahead of you there Ian Don't waste your time (concentrate on bearing carrier repair ) a cheap metal poker does the trick usually about £3, (they get named ) saved myself previously(drove on her for a month) and then another driver at syncro25 from disaster, Matlida saved a guy in Devon and guess what they also double as a poker aswell

[silverbullet]

That's all well and good but if you need the poker to drive, what do you tend the fire with? Maybe I'll just make one for our syncro (or should I just reinforce the lever and have an end to it? No good having a repair piece if the mem'sahib snaps the lever off down the shops )

Anyway, here's the 5-speed version ready to fit:



Yes, it does need a new boot and cap...

[Aidan]

cool, looking good; pop a pic on general to attract some apathy
have you got a before picture too

[silverbullet]

Good point Aidan, I'll still have the shrapnel so I'll take a snap and get posting!