This morning I felt like fitting my 1.9L Z3 kit to the tranny, and making sure everything was good and tight before getting the tranny in the car.
After fitting it I decided the amount of slop in the shift knuckle, and the rubber bushing that mounts the shift carrier was unacceptable. So heres what I did.
I took the shift knuckle sleeve off, and drove out the pin. Took the knuckle off the shaft. Replaced the shaft seal while I was there, because I knew it leaked. The small rubbery cap inside the knuckle was virtually gone, deteriorated from old age, and grease. I removed it and replaced it with a 3mm long section of fuel hose. I then pressed the knuckle on for all I was worth (hella hard to get on all the way with that extra rubber in it) then with some luck I managed to drive the pin back in and replace the sleeve.
When all was said and done, the knuckles side to side movement was reduced 2/3, and it was nice and stiff.
Onward to the next task>>>
Who here has tried to remove the bitch clip with the tranny still in the car? (raises hand) Its a BITCH!! Honestly there is no reason for it, poor engeneering IMO. Also in this area is that black rubber bushing on the end of the shift carrier. It is what is pinned in place by the bitch clip. Once installed, even if a brand new bushing, it allows for a horrible 30º side to side movement in the shift carrier... all of that translates into slop for you and me, and it is unacceptable.
I took the carrier off, layed it in the vise and pressed out the bushing. Took it with me to the hardware store and picked up a brass bushing of quite similar outer diameter. When I got the brass bushing home I found it was too big to be pressed in, even by force. I took the Dremel out, with a standard 80grit sanding drun on it and quickly ran it in and around where the bushing needed to be. I didnt remove much material at all, just cleaned it up and made it smooth if anything.
After that the bushing pressed right in, with a bit of force, but just right IMO. I centered the bearing on the carrier then sized it up to where it had to fit on the tranny. It was a bit too wide. So i cut 2mm off one end, and filed it down smooth again. Now it fit perfectly, again not super hard to press in, but more then tight enough.
I found a bolt in my spare hardware bin that was the exact same size as the inner diameter of my new brass bushing. I drilled the 2 holes on the carrier mount ears to be the same size as the bolt.
The I just drove the carrier into position, pushed the bolt though, and tigheted it up.
After all that I was left with at MOST 2º of side to side slop in the shifter assembly. Which is basicly nothing. I'm happy, the bitch clip is gone, and the shifter is one tight mo fo.
Pictures:
After fitting it I decided the amount of slop in the shift knuckle, and the rubber bushing that mounts the shift carrier was unacceptable. So heres what I did.
I took the shift knuckle sleeve off, and drove out the pin. Took the knuckle off the shaft. Replaced the shaft seal while I was there, because I knew it leaked. The small rubbery cap inside the knuckle was virtually gone, deteriorated from old age, and grease. I removed it and replaced it with a 3mm long section of fuel hose. I then pressed the knuckle on for all I was worth (hella hard to get on all the way with that extra rubber in it) then with some luck I managed to drive the pin back in and replace the sleeve.
When all was said and done, the knuckles side to side movement was reduced 2/3, and it was nice and stiff.
Onward to the next task>>>
Who here has tried to remove the bitch clip with the tranny still in the car? (raises hand) Its a BITCH!! Honestly there is no reason for it, poor engeneering IMO. Also in this area is that black rubber bushing on the end of the shift carrier. It is what is pinned in place by the bitch clip. Once installed, even if a brand new bushing, it allows for a horrible 30º side to side movement in the shift carrier... all of that translates into slop for you and me, and it is unacceptable.
I took the carrier off, layed it in the vise and pressed out the bushing. Took it with me to the hardware store and picked up a brass bushing of quite similar outer diameter. When I got the brass bushing home I found it was too big to be pressed in, even by force. I took the Dremel out, with a standard 80grit sanding drun on it and quickly ran it in and around where the bushing needed to be. I didnt remove much material at all, just cleaned it up and made it smooth if anything.
After that the bushing pressed right in, with a bit of force, but just right IMO. I centered the bearing on the carrier then sized it up to where it had to fit on the tranny. It was a bit too wide. So i cut 2mm off one end, and filed it down smooth again. Now it fit perfectly, again not super hard to press in, but more then tight enough.
I found a bolt in my spare hardware bin that was the exact same size as the inner diameter of my new brass bushing. I drilled the 2 holes on the carrier mount ears to be the same size as the bolt.
The I just drove the carrier into position, pushed the bolt though, and tigheted it up.
After all that I was left with at MOST 2º of side to side slop in the shifter assembly. Which is basicly nothing. I'm happy, the bitch clip is gone, and the shifter is one tight mo fo.
Pictures:
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