924Board.org

[Smoothie]

The shifter for Audi-based gearboxes has a pin that wears to an egg shape over time.
As it wears, the lever feels sloppier and eventually shifting into reverse becomes difficult.

The fix involves cutting off the old worn pin,
drilling and tapping for an M10x1.5 partially threaded bolt,
grinding down the head of the bolt some,
drilling-tapping the edge of the lever for a setscrew,
and reassembly with threadlocker.

showing worn, egg-shaped pin and a 10mm bolt -


shifter after the worn pin was cut off and the area ground flat -


using a drill press to get a clean, straight hole (a slightly undersize bit was used) -


starting the tapping with the same setup, but with the drill having been replaced by the tap -
now the drill press is powered by hand for a few turns to start the tap in straight -


finished the tapping with a T-handle -




found a partially-threaded M10x1.50x50mm bolt and went with it instead of the fully threaded version -


miscellaneous width and length details -


the edge of the shifter was later drilled & tapped for a small setscrew to immobilize the M10 bolt -


used a short piece of re-bar to hammer on while reinstalling the lever -


the shifter boot got some attention while I was in the area -



the original topic on it - http://www.924board.org/viewtopic.php?t=14560
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"..it's made in Germany. You know the Germans always make good stuff."


'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

[Min]

I did a modification like this awhile back (read 5-6 years) and the bolt I replaced the pin with eventually worn the shift rod down enough that I had more slop in my shift than before.

To fix this I machined a new peice out of mild steel that would fit skate board bearings(608z), cut the end off the old shift rod, installed(welded) my new machined peice, pressed some bearings into it, and reassembled. Now when things wear out, I can just replace whatever did (bearings or bolt) Its all very very tight now.

Just gotta upgrade the linkage on the tranny now.

Min
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Custom means it didn't come from a box.
1980 n/a with EDIS and Megasquirt II Injection. 7 different colors and counting.

[Jakkq]

I knew there was some reason It took 5 minutes to get into reverse the other day! Damn. I'll have to look into this idea. Thanks for this information.

How do I get down to getting the shifter out? Maybe I'm just missing it.
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1979 Porsche 924- Snailshell
http://porsche924workblog.blogspot.com/

[!tom]

I believe the '79 comes with the Snailshell transmission, which is different than the Audi unit described here, complete with different shift linkages.
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78 924 NA
5-lug

[Rich H]

[Min]

[Min]

Ok, here are the pictures I promised, I notice people are still replacing their shifter pins with bolts, because the bolt material is much harder than the rest of the shift linkage it accelerates wear. The below pictures are the solution.



All bolted together, the way its been since I installed it. I have not had to do any maintenance on this at all since I put it in (years ago). This is the first time its been apart.



First bearing revealed. As you can see its been pressed in. (which was done on the car using a C clamp)



Here is the hole I threaded into the shifter. I threaded this, and also used a nylock nut on the other side to act as a jam nut and a lock nut, it did not come loose at all since I installed it, and it was still very tight when I took it apart for pictures.



The other side, I cut off the bolt because I didn't have one the right length at the time. When installed I used some large washers between the shifter and the bearings on both sides, so that if the washers wore I could just replace them. I made this piece on my lathe, and then welded it in place while the shift rod was in the car (welding looks like crap, didn't intend to show it to anyone and the mig used wasn't very nice).

Min
_________________
Custom means it didn't come from a box.
1980 n/a with EDIS and Megasquirt II Injection. 7 different colors and counting.

[Rich H]

Wow, better late than never!
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1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec

[Min]

:p

Min
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Custom means it didn't come from a box.
1980 n/a with EDIS and Megasquirt II Injection. 7 different colors and counting.

[KDJones2000]

This fix has been around since 2003, and is an inexpensive fix that can easily be renewed if the bushings wear out:

http://www.dietersmotorsports.com/tech/tech-july-03.htm

You can actually do this entirely inside of the car, just pull the rod up enough to drill it out above your console.

I did this on my car, and it's been great for the past 3 or so years.

Cheers, Keith
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1987 924S SPEC car
Team Toofah Racing
1988 944 Turbo S

[Min]

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