No gears..............

[scam75]

Last few weeks 2nd been getting more notchy and harder to get into reverse and gear stick not exactly great! Recently fitted a new front shift lever so inspected that and all was good at the cabin end. Loosened the 2 x 13mm bolts to try and adjust and it got worse and worse till the point I couldn't select a gear.

I haven't inspected the gearbox end yet, dark and wet and car lives outside, but having looked at images I took of my new box and the short shift rear linkage on it, my money is on the bolt been working its way loose that connects the linkage to the shift lever on the box, the one that seems to have 2 x 13mm nuts, and 2 x large washers on either side of the gearbox shift lever, if that makes sense to those who are familiar!

I'm also hoping that as it finally gave way on the driveway, anything loose or fallen off shouldn't have got far. Weather looks fair tomorrow so will get it up on axle stands for inspection.

My question is, is that nut and bolt and washer set-up anything special? Can it only tighten so far so as not to crush the washers too close to the gearbox shift lever? I can't tell from the pictures I took.



Thanks in advance as ever!

 

[blade7]

It was quite few years ago that I fitted a Shark Motorsport linkage to my turbo gearbox, and I seem to recall some or all of the bolts were supposed to have thread lock on them.

 

[scam75]

Yeah that's correct, and as I never fitted the linkage, that may not have happened! Gonna jack it up at lunchtime and have a gander.

If indeed what I think has happened, I'll stick a nylock nut on it and try and double nut it for the time being.

Cheers

Stuart

 

[russmw]

I followed the rennlist thread about 8 years ago and rebuilt the factory linkage for minimal cost and built a solid version of the brace that goes to the top of the gearbox using a couple of tie rods.

Transaxle linkage rebuild project - Rennlist - Porsche Discussion Forums

924/931/944/951/968 Forum - Transaxle linkage rebuild project - I've been working on this for a little bit and am looking for good ideas... I hate all the play in the shifting (already rebuilt in-cabin shifter) and a new linkage isn't in my budget right now. Plus, rebuilding OEM parts is cooler...

rennlist.com

All made the gear change much more positive and took out 90% of the slack,

 

[Eldavo]

I’d check the bolt in the bottom left of your picture - it holds the whole linkage onto the shaft and has a pointy end to locate it in the shaft. If it comes loose then it becomes increasingly difficult to select gears - ask me how I know - use plenty of thread lock when refitting.

 

[scam75]

Eldavo is on the money! It was indeed the pointy ended screw that holds the whole linkage on. Must have been loose for ages, maybe even since the box was fitted, before it finally made its way off the shaft (oh err, careful missus!), as the end result (read on) is way better than its ever been.

Simple fix. eh? No. Did not have any thread lock to hand, will get some soon. So put the linkage back over the rod and tightened the bolt, of course I over did it and stripped the bolt thread! Never mind, had another (almost) suitable bolt, fannied about with shims, washers and a nut to make it the right length, then managed to strip the thread inside the linkage! Awesome work Stuart!

Never mind, remove the bit of linkage, quiet smart how these short shift after market jobs are made, and re-thread it a bit bigger. Done, then did not have a bolt to fit!

Popped round to local garage, turns out I put an odd ball thread on it, couldn't get a suitable bolt. So we we tapped it out a bit bigger again, got a suitable bolt, cut it to length and grinded a pointy end on it. The bolt is now a fair bit larger than standard. Located it and got a real decent tighten on it without any stripping (careful!) and all is well with a very nifty, very short shift.

All in a days work..........

Stuart

 

[russmw]

Doesnt the pointy screw have a small hole in the head so it can be wire locked in place? the factory 924 one does, seem bit of a weird thing to miss out on an upgraded one??

 

[scam75]

No, it's a pointy screw bolt with no hole or lock mechanism, or at least it is on my after market short shift. But at the other end where it connects to the selector rod, mine has a castle nut and split pin arrangement (as you can see in my picture). This is essential here as that bolt isn't fully tightened as the mechanism needs to rotate in the washer/bearing set-up. I completely agree a lack of locking the pointy bolt/screw is not the greatest idea!

Here is a standard one:

Porsche 924 944 manual linkage for 5 speed gearbox, used | eBay

Porsche 924 944 manual linkage for 5 speed gearbox, used Porsche 924 944 manual linkage for 5 speed gearbox, used. © Rare Porsche Parts. Genuine BBS RS Hex Cap Large Tall Wheel Center Set of 4- 0924015 used.

www.ebay.co.uk

Can't see exactly but it looks to also have a pointy screw bolt. I'm sure when its thread-locked in it will be fine. Ordered myself some yesterday. Once I feel any play in the shifter I'll get it on the bolt. Hopefully be a bit warmer by then, or if its on a ramp any time soon, I will attend to it then!

Stuart

 

[blade7]

I'm pretty sure the bolt with the pointed end was lock wired on my Turbo, it fits into a detent on the shift rod. As shown in one of the pics in the russmw link. The lockwire means it doesn't get over tightened, and stripped .

 

[scam75]

Yes, yes, I'm a clown ! Definitely no locking arrangement on my kit.

Must say, the short shift really is a short shift with my kit, and very precise. That bolt/linkage must have been floating about for 1,500 miles since I installed the new box before it finally exited stage left as I ain't felt any really short shifts, a tad shorter maybe then before but not as short as it is now the bolt is tight..................anyway, I've got an oversized bolt now. must be worth a few more BHP !

I've also had to adjust the front lever (2 x 13mm bolts) as well so the shifter sits in the right place. It was full back on the adjustment before, now its full forward.