Replaced gear linkage bushes but having alignment issues

[Ads1987]

Hi guys,

I've tried looking in the wiki and just spent a good while using the search function but still struggling to find the answer so sorry to ask a common question again. The five speed write up is brilliant but unfortunately I have a four speed box.

I recently replaced the gear linkage bushes and the gear lever base http://www.brickwerks.co.uk/index.php/t ... -14mm.html" onclick="window.open(this.href);return false;, I didn't replace the nylon ball at the box end but it seemed ok; there's still slight play if I wobble the linkage rods underneath but I assume this is quite normal?

Unfortunately due to inexperience I did not adequately mark the selector shaft on disassembly and so was not able to bolt it back in the same position; I'm now having problems getting it out of reverse and third.

I've tried quite a few times now to unbolt it and line it up with various methods but just failing, please can someone give me their best method of aligning the two shafts on a four speed box to get all the gears to work?

Thank you very much,

Adam.

[Aidan]

Make sure cup and ball are properly mated and the protective boot's skirt pulled down the cup
loosen the pinch bolt underneath
have other person move the gearstick to and fro across the gate in neutral a couple of times, then across to the left as if going 3rd 4th
tighten the pinch bolt
should be about right, assuming the nylon tips on the front linkage are in good condition

[Ads1987]

Thanks Aidan,

I think the rotational adjustment is also out, what's the best gear to use as a benchmark to set that up?

I'll check the nylon tabs at the front, I'm assuming these help to locate the gearstick and stop excessive movement?

[sarran1955]

Hello,

Just did mine..


https://club8090.co.uk/forum/viewtopic.php?f=37&t=124770" onclick="window.open(this.href);return false;

I tried the 'Haynes' method..

Having marked the splines ( twice)..

But found a much better result as follows..

2 shafts apart..Engage reverse with the rear shaft.. make sure that the reversing light comes on..

then same thing for the front..(assistant to hold gear lever in place)

Realign shafts and clamp.. look at the 'fade' on the zinc plate to see how far the 2 shafts engage..

Mine 'closed ' completely..

Replace the rear plastic bush..

'Out of context' check.....OK

Hope this helps..

Cordialement...

[Ads1987]

Thanks Sarran that's really helpful, I managed to have a good look around in daylight today and adjusted it a bit.

Found the nylon ball at the relay lever pops out of its cup when in first and reverse, this then hinders gear changing back out of these gears so going to order the parts up.

Just kampers sell the ball without the metal relay lever, is this what you replaced or did you do the metal lever and ball?

http://www.justkampers.com/251-711-221- ... -1992.html" onclick="window.open(this.href);return false;

If so did the plastic ball just pull off the metal lever?

It seems strange that there's not a circlip holding the ball in but assume a new ball is just a tighter fit and won't just pop out.

Thanks for your help, much appreciated.

Adam.

[sarran1955]

Hello,

No other bits than shown in the post..

The nylon 'golf balls' had almost no wear.. so best left alone..

Hope all goes well..

Cordialement,

[DokaDave]

Hi
I had read up on the replacment of the Gear Linkage Bushes and followed severl threads on the subject. I subsequently got the parts from Brickwerks and pencilled in in for the first good weekend when i can get underneath and carry out the replacement in an effort to tighten up my box. but my hand was forced when the gearstick came off in my hand in the middle of town on Tuesday afternoon in the rush hour. Following my What the blithering heck moment:D I mangaed to limp it home and decided now was as good a time as any to undertake the works, so following reconstructive surgery on my gearstick, I came to rebuild the assembly which i thought would be straight forward, but I have problems with the setting, realighment and making it all work smoothly following the Gear Linkage Bush replacment and subsequent rebuild. So here I am!!!
Aiden mensions about nylon tips in the thread . my question is do late syncro have the nylon tips fitted?? Those on mine do not appear to have anything only bear metal whose face is approx l =15mm w =7 mm, they do not compare to Henrys photo shoot on the subject at all.
If i need some where can i buy some or have i got to manufacture them myself??
Also when setting up the spring tension and retaining collor where should the lever sit where is its natural position? The collet to which the spring sits at the ball joint end should this be free as i am unssure if it should be fixed at a point on the shaft.
I am very conscience about some comments on here from aiden about the gear levers natural position so i dont want to give the gear linkage an unnatural position and cause further problems

Any help and guidance is gratefully accepted

DD

[Ads1987]

Hi dokadave,

I had similar problems to you when replacing my linkage, when I get back from work I'll find out all the useful threads that were shown to me and show you the links.

I found the best way to align the gears was to put the gearbox in 3 and then the gear stick in third, then push the splines together and have a friend hold the gearstick in neutral but as far right as possible. So basically holding it between third and fourth to get the shafts at the right length.

I have the same issue with the completely worn nylon pieces, brickworks sell them, I haven't brought them yet but that causes a large amount of slack in the gearstick that I too am still having problems with.

Will come back with more info later!

Adam.