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Stiff gear change!!

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nick3814

New member
I've had my 1986 944 lux just over a year now and I've noticed 1st and 2nd seem to be getting rather stiff, especially when cold!! Theres no issuse with any other gears just changing from 1st to 2nd and vice versa it eases a little as it gets warmer but isn't great. You can feel (not hear) the mechanical crunch as it engages if you know what I mean. I changed the gearbox oil at the begining of the year for Swepco 201.

Is there any adjustment that can be made?

Have any of you had a similar problem?

Cheers
 
It's worth getting under the gearbox and lubricating the mechanism as it gets all the heat from the exhaust rear box.

The changer is on top of the gearbox on the exhaust side, try soaking it in penetrating oil and then once freed up give it a squirt with aerosol grease to protect and seal it
 
They can be pretty stiff when cold anyway. Mine has been OK through the summer but now the temperature has dropped i've noticed a significant increase in the stiffness and un-willingness between 1st and 2nd gears on both the upshift and downshift. It is better when everything is warmed up but not as good as it has been all summer.
 
there's a plastic "knuckle" with two bores thru it. It has rubber seals to keep the shafts clean. Over time corrosion builds up and converts the beautiful original change quality into a wrestling match. The knuckle is originally molded from some cheap plastic material, possibly as bad a nylon. It ages with exhaust heat/time.

I had new knuckles made in Acetyl, and smothered them in grease. I used 3 degrees as the bore offet angle as they are slightly off square. I left the seals off as they prevent future lubrication.

Brilliant result !

George
(I wasted a full tin of WD40 on it before this !) - a spare knuckle set from OPC was £75-00 each (I needed two)

944t
 
Oli, an engineering company in Garvagh, N.Ireland, very high quality work, we use them quite a bit with my work.. I have attached a sketch I made and can ask him to make more if you want.
I got them as part of an order for various components for a machine, so cannot tell you a cost.

Let me know if you are interested.

George
 
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