Overhauling 5 speed gearbox linkage

[mm289]

MM

[CovKid]

Article updated as of today to reflect changing prices and stock availability.

https://club8090.co.uk/wiki/Ge ... hanism_Pt1" onclick="window.open(this.href);return false;

[RustyShackleford]

Thanks very much for the wiki guide. I did pt1 on my van this weekend.

I followed Covkid's advice and used some hose to replace the worn fork ends.
I found 16mm coolant hose was a perfct tight fit -

[CovKid]

It may be a little soft though. Ideally you want a reinforced nylon type and you'll need to use araldite or something similar so they don't move. I actually used metal putty on mine which worked well and available in all the £1 shops these days.

You can buy replacements now ofcourse but nowt wrong with DIY as long as it works

[itchyfeet]

Anybody interested in pics of the four speed for the wiki? Did one at the weekend most is the same but the gearstick end is different and much more simple, if you want them i will write something up

[CovKid]

Yes please. It took ages to put the five speed one together but we could do with a four speed one. I'll happily tidy it all up for you. Its also encouraging to see practical and simple solutions to long-known problems.

[what2do]

Go on, you know you want to!

[itchyfeet]

Ok will do but may take a few weeks

[Paul Murray]

Hi all. First I'd need to say this a great place for info. Thanks to everyone.
My 19 yr old son has been bitten with the Kombi bug. He spent a year travelling Europe in a Kombi and returned to Australia just a few weeks ago and bought a 1990 Manual T3 petrol Transporter. The problem is, he is not mechanical and I have volunteered to teach him a few things. Just so I look like a guru in his eyes I am trawling the net looking for instructions on how to fix things. One of the tasks is to rebuild the gear linkage that is directly under the gear stick. This thread is brilliant. His kombi has nothing attached (no clinch pin, no ball bearing - nothing) I have ordered what I think are all the parts, except the boot is the wrong one --sigh. It takes 3 weeks to get stuff delivered to Australia.
If MM289 is still following his thread, or anyone else who has done this repair, can you answer this please:
MM289 said the clinch bolt will only come out one way, which is back through the housing on the gear stick. I am yet to attempt the repair, but looking at the parts I cannot see what will stop the bolt from sliding out in the direction the spring is pushing it. I think the detent ball can jump the groove in the bolt both directions. Is there something I can't see? Is there something in the housing that stops the clinch bolt sliding all the way through the housing?
Thank you

[mattf]

Now PROCEED CAREFULLY, because the detent is created by a ball bearing under pressure from a spring which pushes against a collar on the pin, if you just shove the pin out the ball bearing will pop out and run away – go on ask me how I know.

Thanks for the excellent guide to dismantling the lever assembly. Followed all the advice - including catching the elusive ball bearing!

I'm now at the stage where I need to put it all back together, but I can't work out how to slide the pin back in while compressing the spring with the ball bearing on top. Any tips or techniques?

Cheers
Matt

[CovKid]

I can't take complete credit for gearbox WIKI articles as Itchyfeet did so much documenting on it so did MM289. We sort of worked together on it based on all our experiences and using everyday objects (at times) in order to get the job done. Its a lot easier than a Haynes I'll say that and no doubt both 4 and 5 speed WIKI's are read the world over now. Pain to E D I T though.

[BigSean]

Just wanted to say Thanks.... what a brilliant guide.

[CovKid]

Glad it was helpful.

[ghost123uk]

Yup, great write up folks

I have just been studying it as it's time to do mine (4 speed).

[Smiffo]

Hi all.

Just browsing here, as my gears are floppier than Bugsy's ears..!!
More annoyingly, when it's cold and the revs are slightly higher, it crunches into second unless I go to third first, then back to second.

Thought I would look at my van to see how it compares to these, and it would seem mine looks totally different...
The surrounding `box` has extras attached to the side, but the most obvious difference is that there is no part that the rubber bit goes on in my van.

Laymans terminology here I know, so here are some pics.

It's a 5 speed gearbox.
Anyone know if mine is right for a 5 speed, or is there actually something missing?
Is it an older / newer design than the pictures depict earlier in this thread?

Thanks in advance.