Shifter assembly

Well, here is the first weekend in many that we did not go away.

Cub Scout event yesterday, and forecast for heavy thunderstorms all over New England kept us local.

So I had time to play!

First task on list was to rebuild my shifter.  It's been getting sloppier lately.

Had a kit from Go Westy, and a shifter ear repair kit from T3 Technique ready.  It's really easy, and the diagram in the Bentley in section 34 should be enough to provide confidence that you can do this too.

First, remove the boot from the shifter shaft.  Then cover the area around the shifter assembly with newspaper, rags or whatever you have.  You wouldn't want an old greasy part to make its mark on your nice carpet.

Remove the set screw in the collar above the tension spring, then remove the two 10mm nuts holding the assembly to the body.

The kit has all the parts you require to replace this entire assembly, so put it aside where it will not be in the way.

The metal housing comes in bare metal, so I took the opportunity first to clean it with some cheap enamel reducer and paint it.  While it is drying, build the new assembly - larger diameter spring goes inside the two ball halves.  Then this assembled ball goes into the two cup halves.  Lubricate liberally while assembling - I used a waterproof grease. 

The cupped ball assembly goes into the rubber 'gear looking' part.  A bit of grease will aid in the insertion (isn't that always the way?).  This new assembly is now at the point where it can be left without fear of it blowing apart.  

When the metal housing is dry - took minutes in the 85 degree sunny heat of today, you can insert the rubber enclosed assembly into the back of the metal housing.  Again, a spot of grease will aid this insertion. There is a round plastic retainer that follows the rubber encased assembly, and will locate the  shifter ball in the correct position when assembled.

Now this next part can be done from above, but since I was doing the 'ears' of the linkage as well, I moved to the underside of the van.  If you are going underside, you can reinstall the assembly using the new nuts and washers, locating the added two holes in the metal housing with the corresponding holes in the floor plate.  The later models do not have this hole, and the Bentley should be referenced for proper placement of this housing assembly.

I removed my clamshell, as I have it on stainless bolts instead of the retainer springs that normally act as the hinge pins.  This gave me freedom of movement.  

Some people like to keep the clamshell attached, and use it as a back support while working in this area.  To each their own, I guess.  With the van on ramps, I can sit under there comfortably upright and have plenty of room with it removed.

Locate the shifter assembly box.

Remove the fasteners holding on the box.  Some PO had been here before, judging by the stainless nuts and washers, so removal was easy.

Inside, you will find this (in some form or another):

De grease and clean the linkage so you know what you are dealing with.

Here you can see the bolt head, nut and a piece of the linkage 'ear' hanging off to the left.  No wonder its getting sloppy.  

Disassemble the bolt and nut.  Remove it carefully as the loss of tension will cause the shifter to lop over above from gravity and could pinch your fingers.

Clean it more if necessary.  There are two bushings in the base of the shifter that get replaced.

The ears get yanked.  They are plastic with a simple locator dowel in the middle.

Clean it, and slip on the new ear pieces, paying attention to the differences in size and shape.  The square one goes in the drivers side, and the one with the slanted top goes on passenger side.

The kit comes with two aluminum dowels that get pressed into the plastic, and through holes in the linkage ears.  I used a simple clamp to do this, and made sure to file off any excess.

Reassemble the linkage bottom with the new provided bolt and nut.  

Now, degrease the housing box.  Check it for too much wear.  If its good, slather the guides with some waterproof grease, and reinstall.

Before reassembling everything, give the shifter a try.  Make sure it shifts correctly, and smoothly.  It should feel fantastic and make you want to drive it just to enjoy its glorious workings.

All good?  Reassemble your clamshell, check the air in your spare and its condition, and button it all up.

Enjoy!