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Tcash
Samba Member
Joined: July 20, 2011
Posts: 12844
Location: San Jose, California, USA
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 Posted: Tue Jan 28, 2014 3:25 pm Post subject: My fix for a sloppy new front shifter bushing |
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| FNGRUVN wrote: |
My fix for a sloppy new front shifter bushing
I was having trouble finding second gear on my newly acquired '77 Deluxe so I ordered a shifter bushing kit from Bus Depot. When I installed the new bushing for the front rod I noticed that it was really sloppy in the hole. I took it out and compared it to the old bushing and sure enough it was more than 2mm smaller(old=26mm, new=24mm). To make things even worse, the hole was wallowed out on the sides. I looked at my other bus that I just bought and it's the same way. This must be a common wear pattern for buses. This is my first experience with buses, so I'm learning as I go.
I found out that all the new bushings are made at the same place so this means any kit I would order would come with a bushing that's 2mm too small. What to do? Well, today I just went for it and cut the old bracket out and welded a new, better bracket in. Here's some pics:
Old bracket with wallowed out sides
Cut out the old bracket(you can kind of see the oval-shaped hole
I used the old bracket as a template on some 3/32" sheet steel and marked the center of the hole the best I could and drilled a pilot hole.
Used a 7/8" step drill to make the hole then I had to ream it the rest of the way with a die grinder(24mm). You can really see how wallowed the hole was here.
Put the new bushing in to test fit the rod.
Cut out the new piece and held it in place with magnets to tack weld it.
Installed rod just to check shifter operation.
The shifter is nice and tight now. I still have to change out the other bushings and the transmission/shifter rod coupling. I hope this improves the shifter even more.
There's still some rotary play in the shifter. I'm guessing there's some slop between the pin that protrudes from the ball and the slot it rides in. Anyone ever build this up with a weld and grind it out to the right size? There's also a flat spot on the flange above the ball where it rides on lock out plate. Can this be built up and resized?
One other question: when Bentley mentions the shifter should be 90 degrees from the floor while in second gear, is this so your knuckles don't go into the dash when shifting to first and third?
Are the stock aftermarket shifters any good? |
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FNGRUVN
Samba Member
Joined: October 27, 2007
Posts: 2237
Location: Fort Collins, CO
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| Posted: Tue Jan 28, 2014 8:37 pm Post subject: |
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I thought that title looked familiar. I have another bus that has a slightly wallowed out bushing hole, but instead of welding in a new piece, I thought about tacking a bead around the hole and then ream it out to the right size. Then just grind the weld down a little so the groove in the bushing would fit right.
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vwwestyman
Samba Member
Joined: April 24, 2004
Posts: 5688
Location: Manhattan, Kansas, USA
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| Posted: Sun Feb 12, 2017 8:11 am Post subject: Re: My fix for a sloppy new front shifter bushing |
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Thought about doing all this work yesterday. But it looked like my bushing hole was still pretty round, vs wallowed out somehow.
So I was afraid that if I went to all the work of cutting the hole to the spec'd size, I'd have the same problem of a loosey-goosey bushing.
So I contemplated other options, and decided instead to try to make the outer edge of the bushing's diameter a little larger instead.
All I did was find a zip-tie that fit snugly in the bushing, cut it to length to fit in the diameter, and put it into the bushing. Then when I installed the bushing, it fit snugly in the original metal piece on the bus. I attempted to super glue the zip-tie chunk into the bushing but I don't think that is actually necessary if you are quick and deft in how you push the bushing into place.
After installing it, the shift rod is nice and snug.
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President, Wild Westerner Club
1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
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cmonSTART
Samba Member
Joined: July 15, 2014
Posts: 1915
Location: NH
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| Posted: Sun Feb 12, 2017 8:21 am Post subject: Re: My fix for a sloppy new front shifter bushing |
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That's interesting. My new front bushing fits a bit loose too, and as far as I can tell the hole is still pretty round. I might give that a shot!
I actually thought about trying to work some JB Weld in there to tighten things up. Or maybe use one of those Bondic pens.
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KentABQ 
Samba Member
Joined: September 11, 2016
Posts: 2406
Location: Albuquerque NM
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| Posted: Sun Feb 12, 2017 8:50 am Post subject: Re: My fix for a sloppy new front shifter bushing |
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In order to tighten the hole diameter slightly, it might be simpler to install a caterpillar grommet. It can be cut to length to fit any size hole in sheet metal. And can easily be glued in place with RTV or super glue.
The difficult part is finding a source for caterpillar grommets. I find them occasionally in electronic kits, but haven't been able to buy them at Radio Shack. |
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vwwestyman
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Joined: April 24, 2004
Posts: 5688
Location: Manhattan, Kansas, USA
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Wildthings
Samba Member
Joined: March 13, 2005
Posts: 50338
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| Posted: Sun Feb 12, 2017 10:30 am Post subject: Re: My fix for a sloppy new front shifter bushing |
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| Around ten years ago, I had lost the OEM bushing and installed a cheap bushing from a local VW place to get me going again. That bushing lasted only a few months before failing while I was out on the road. Not wanting to sit for days waiting for a better bushing to arrive I cut a strip out of a plastic oil jug and wrapped it around the shaft. After some experimenting to find out how long of a strip gave the best fit the shifter worked very well. I just used wire ties to hold the new "bushing" in place fore and aft. I hadn't intended this to be a long term fix, just a get home fix, but I left it in place for many years. |
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airschooled
Air-Schooled
Joined: April 04, 2012
Posts: 12721
Location: on a bike ride somewhere
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| Posted: Sun Feb 12, 2017 12:33 pm Post subject: Re: My fix for a sloppy new front shifter bushing |
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If your late bus shifter system is fairly libricated, a late bug shift bushing will fit and work well enough to get you home without grinding any gears.
Colin also used a headrest escutcheon once, I heard that worked well.
Robbie
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Yarkle
Samba Member
Joined: August 03, 2009
Posts: 1218
Location: the Hills of Western Maine
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Wildthings
Samba Member
Joined: March 13, 2005
Posts: 50338
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| Posted: Sun Feb 12, 2017 1:41 pm Post subject: Re: My fix for a sloppy new front shifter bushing |
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| Yarkle wrote: |
| KentPS wrote: |
In order to tighten the hole diameter slightly, it might be simpler to install a caterpillar grommet.
The difficult part is finding a source for caterpillar grommets. I find them occasionally in electronic kits, but haven't been able to buy them at Radio Shack. |
I found some here!
http://www.aircraftspruce.com/catalog/appages/grommetedging.php |
Anyone know the necessary thickness? |
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BusPriest
Samba Member
Joined: October 08, 2014
Posts: 420
Location: Denver, Co
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| Posted: Thu Feb 23, 2017 11:11 am Post subject: Re: My fix for a sloppy new front shifter bushing |
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I found a small rubber band and wrapped it a few times (3x) around it. Put it and seems to take up the slack! Good luck
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