Gear linkage fun

[robdimond]

Been taking advantage of the time off to do some Porsche jobs. Rear brake lines all done... the old ones literally crumbled to bits in my hands. []

While it's up high axle stands I thought I would fit the shiny new short shift linkage from only944. After much swearing I've got all the bolts undone, but the lever that bolts to the selector shaft is stuck solid. Tried WD40 and putting a puller on it, no joy. I'm resigned to drop the gearbox so I can get access to cut it off (will also make fitting the rest of it much easier). I didn't want to put too much force on it in case it shears off something inside the gearbox.

Any tips/tricks before the gearbox comes out??

 

[andy watson]

Hi Rob, hope you had a good Xmas
Looks like you are in for another round of love or hate the 44 [], have you tried Plusgas?
They do a spray can as well as the standard oil tin, really good stuff and worth a try before dropping the box, may save a little grief

Good luck

 

[edh]

Daft question I know, but you have removed the screw that locks it in place?

 

[robdimond]

Yes I did get the screw out! It was loctited in so that was fun in itself.

Good call on the plus gas Andy. I've used Rost off in the past which is also very good. After contemplating a bit I'm going to give it one more go tomorrow and then look at cutting it off in situ. It looks like the linkage is ally so I should be able to drill it and then break it off.

If all else fails then I'll drop the gearbox and sort whatever mess out. Would be nice to see in the new year with a driveable car...

 

[chrisg]

Rob

for what its worth, I'd drop the box off and work on it rather than struggle underneath and cause yourself lots of additional hassle.

Chris

 

[robdimond]

All done!

She put up a good fight, but managed to drill it under the car and avoid dropping the gearbox.

Even with the chunk cut out, it still held on!

 

[blade7]

I made a little U shaped puller out of flat bar, wound a bolt through onto the end of shaft and pulled the linkage off.

 

[George Elliott]

Good bit of drilling Rob, the heat from that may have helped expand the linkage bore. I was hoping you would not need to drop the box.

Like blade7, I made a puller.

Mine involved a large Nut cut open to resemble a horse-shoe (which located against the back of the linkage you drilled) with two side flanges welded on. Across these I put a 5mm flat with an M10 thread centred on the shaft. Slide in place, fit a bolt and tighten to remove.

It has worked each time but if not used carefully it would break.

good start to the year []
George
944t

 

[robdimond]

Took it round the block today (no further due to ice and fog everywhere). Gearshift is totally transformed! Highly recommended upgrade for anyone still on the original linkage.

 

[zcacogp]

ORIGINAL: robdimond

Took it round the block today (no further due to ice and fog everywhere). Gearshift is totally transformed! Highly recommended upgrade for anyone still on the original linkage.

You don't need a short shift linkage to achieve this - simply replacing the old worn parts with new standard parts will achieve much the same end result.

However I strongly agree with you that it's a very worthwhile exercise! It's amazing how much more satisfying to drive a car with a tight gearshift is than one with a loose, imprecise one.


Oli.

 

[Chrishazle]

On the guess that 944 and 968 manual gear linkages are similar, you should ask Waylander about what he achieved for pennies with his 968 linkage rebuild - he's amazing at finding cheap but good ways of fixing things, latest being the water pump, he's also done the starter motor and, I think, an alternator, all for considerably less money than anyone expected!

 

[robdimond]

After looking at the original linkage, I can see how it has developed loads of slop in the plastic linkage through rust and years of wear. I'm sure you could get a significant improvement by machining a new bush for these, (or shimming with bits of boddingtons beer can... isn't this what Rob W did?).

However, the original still has rubber bushes which are tired and even new ones are going to introduce some slop vs the rose joints in the aftermarket linkage. I've not priced up the original bits from Porsche but I would be surprised if it's much cheaper than the after-market short shifter.

If anyone wants my old linkage to steal parts from or experiment with then let me know and I'll put it in the post. Obviously part of it is destroyed! Although could be welded and re-machined quite easily I think.

 

[Waylander]

Thanks for the vote Chris, the 944 and 968 linkages are quite different due to the extra gear in the box but a new one from OPC for the 944 is about £140 (comes as one part) 944 424 013 02.

the 968 one also comes as one part 944 424 013 01 £157.80

they are both called intermeadiate shift levers

 

[zcacogp]

Martin,

What are the good-value fixes you have achieved for the linkages, water pumps, starters and alternators? I'd be quite keen to know - particularly if they can be applied to the 944.


Oli.

 

[Waylander]

Hi

you can rebuild your starter for about £30.00, the same for your alternator, the linkage can be rebuilt on the 968 with rose joints and nylon bits from only944 for about £50, i can get water pumps refurbished as long as they have steel impellors for about £100.

I have even made my own rear drop links with rose joints for about £20.00.

does that help

 

[Mikebarry202]

Interesting thread so far, continuing on the same theme ('ish) I'd be grateful for some advice about my vibrating gearstick!

Having stripped apart the main gear lever housing to have a general look around, the main shaft is not worn at all but there is a small amount of play where the ball joint sits in its white plastic socket. Can anyone advise whether the plastic socket/bush can be replaced on its own or is it better to replace the lever (with ballpoint) as well? Does it come with a new main gear lever?

Many thanks in advance......

 

[Waylander]

yes it can

944 424 231 01 £1.72.

put it in a cup of hot water before fitting it or it will crack in half

 

[Mikebarry202]

Thanks Waylander. Typical, postage is twice the price!

 

[Waylander]

mike pm me your address and I will get Porsche to send you one free post, only if you send me £2.00 for the part[]

I will order it and have it sent direct to you, I buy so many bits and pieces from them its like a main parcel place here