Club 80-90 Forums

Today I fitted the Gear Lever Repair Kit, purchased it from Brickwerks and must say the service from BW was first class. I followed the instructions in the Wiki and the guide as explained by Covkid and MM289 was superb. I printed it out, all 21 pages of it, to have to hand during the repair.

Mine's a 1.6 td 5 speed.

The fix seems to greatly improved the gear selection process although I may change more parts in time to tighten things up further. I have come across one problem however that I would appreciate some advice on. I'll do my best to explain

The assembly at the base of the gear lever, the guide pin and spring bit seems to have been fouling the housing for quite some time. I say quite some time as its ripped a tear in the side wall of the housing. See picture below




After replacing the full gear lever assembly I got a friend to change gears whilst I took photos of the aforementioned problem. See more pictures below

This is how the base of lever sits with lever pushed over for 1st/reverse



This shows the pin going into the groove when 1st is selected



This shows when reverse is selected ( no apparent problem with reverse )



Gears 2 to 5 are ok, no rubbing against the housing on the other side.

Any help much appreciated as we are going away next week and would like to get this sorted if I can.

Thanks again to COvkid and MM289 - your wiki guide is excellent.

Eric

i've got a turbo diesel box for under the gearstick, it's off a syncro so has different fittings in it, I can supply it stripped and you'd have to move the blocks and reverse lock out tab over from yours email me if interested
does your plunger now move freely otherwise it'll muller the replacement

Aidan wrote:i've got a turbo diesel box for under the gearstick, it's off a syncro so has different fittings in it, I can supply it stripped and you'd have to move the blocks and reverse lock out tab over from yours email me if interested
does your plunger now move freely otherwise it'll muller the replacement

Hi Aidan, Yes I would be interested in the box. I'll PM you. Yes the plunger moves freely but any idea why its so willing to travel so far over. From the gear knob end the movement doesn't seem that much compared to before the fitting of new kit ?

Can any gear experts out there point me in the right direction to stop the base of gear lever fouling the housing box. Was thinking step two of MM289's wiki guide ?

It'll come in the adjustment I think. The base of the lever really doesn't need to go that far across to get 1st, plus plenty of grease will help. Its the accumulated wear in components that has caused that issue. Plod on and check that everything is adjusted correctly in terms of travel.

CovKid wrote:It'll come in the adjustment I think. The base of the lever really doesn't need to go that far across to get 1st, plus plenty of grease will help. Its the accumulated wear in components that has caused that issue. Plod on and check that everything is adjusted correctly in terms of travel.

Thanks for the advice. Pretty much what I was planning I just needed someone to tell me I'd be on the right track.

Eric