Club 80-90 Forums

the rubber boot on the gearbox end of my gear linkage has split.Q how easy is it to replace and how does the balljoint come apart? 1.9 dg 4 speed box.

Do you mean the one that is on the vertical bit? where a round onion fits in a cup?

i think that would be a good description of it cate. i have just had a look on wiki (rtfi ian rtfi!) but i am still not sure quite how to take it apart.its the gearbox selector arm, bolted to gearbox then straight down to balljoint with rubber boot over it. its the boot thats split.haynes says to undo the bolt that connects the selector arm to the gearbox but how does the balljoint come apart?

it just comes apart! undo the bolt that holds it into the gear box, then undo the bolts that hold the linkage to the gearbox via a bracket a little further forward, note where this bracket is fixed.
the 'cup' part will drop down and you can clean it out and regrease it and put on a new boot.

nice one cate! so its just held there by being bolted at the bush and the gearbox? new boot and a bit of waterproof gease and i am sorted, ta.

Actually just thinking about it you wont need to undo the bolt at the side of the g'box, just the other two on the bracket that holds the other bushes. give that a clean up too while you have it apart, you may find you may need to change those boots, a little more involved!

i don't want to messin with a good gear change, the two bolts that hold the rod to the gearbox at the bush? if i undo them drop the balljoint reboot regrease and rebolt i will still have 4 gears at the front end yes ? no probs -easy peasy 1/2 hour job? i don't know every time i crawl under my van i find something that needs tlc!

It wont make any difference to your gear selection because you are not changing the length or the angle of the linkages, all you are doing is dropping it down on its own uj, you'll be fine. good luck.

ta cate, feeling like this one is for my own fair hands. will let you know how i get on.

Best of luck, I'm sure it will be all good.

This sounds like a girl speaking from experience!
How many times have you had that apart Cate!

errrr several! hey ive got a syncro!

If the cup turns out to be badly worn, they're still available from VW and Just Kampers. I removed the linkage and pushed the springpin out with an M6 bolt and a vice; the cup then slides off the end of the link rod. The boot is an easy slip-fit over the cup but it's better to slide it over the ball, fill the void in the boot and the cup with the correct grease, then slip the whole lot back together. Wipe off any excess grease and the job's a good'un.

BTW you can rebush the rear end of the linkage without disturbing the adjustment; it's only when you separate the splined joint that Living in Interesting Times begins.

That cup is different on the diesels, longer I think, JK do them do they?

I find the boots never stay over the cup, not long enough, others say different as usual - maybe its the diesel difference. One event is enough to fill the syncro ones up with crap.
Usually worth changing the rear bushes on that main shaft too, but if the man's happy with his gears.....

and doesn't clean, change and regrease, one day the shaft diameter will be worn down and then - WTFDYD

i take your point harryman, so as i would be unbolting the rear bushes to drop the shaft it would be worth splitting it and changing the rear bushes as well. im'e of to study my haynes again! thanks for your replies everyone.