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Team WorldTour Samba Member
Joined: September 02, 2010 Posts: 2426 Location: Der Vaterland
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Posted: Sun Mar 06, 2016 1:25 pm Post subject: Another Broken Gear Shifter! |
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...ya know, not another one for ME, just another broken one....
So, Mrs. WorldTour, myself, and another couple are toolin around in the Bulli, Geocaching, and it's getting on toward sunset (this JUST happened, BTW!).
As it happens, we were illegally trespassing in someone else's forest (it was also snow/ raining), and we get near the cache. I am trying to turn around (between trees), and the shifter feels strange. The position for 'G' and 'R' are WAY too close to my knee. I try to get it into R again, and the shifter just goes loose. I thought maybe it came loose UNDER the van. Nope. I let go of it, and it just flops over. GREAT! I lift it straight up, and it comes right out of the rubber boot.
Link
Thinking quickly, I call out the the woman from the second couple (also a mechanic, and an old coworker) to grab the tool kit and pass me a screwdriver. I jammed it into the broken end of the shifter, and got us out of the woods.
Out on the street, I'm rolling things over in my head. Tow truck to the Army Base nearby, friend getting off work soon to give everyone a ride home while I deal with the van, getting the groceries home, etc....
So I call out again, this time for the Bible. It's time to read Chapter and Verse.
I find my shifter set-up and look at the schematic. Army training kicks in.
Self Recovery.
I look at the pieces available to me. I pass the shift lever back with instructions to find SOMETHING that fits in the end.
I take the locking collar, lift the remaining shifter up, and fix it in place (NO reverse). I get passed up a 1/4 extension (six inches long).
OK. I can work with this. Trust me Dude, I've made a bong with less....
So we are now mobile. As long as I can keep the speed up, I won't have to shift so much (Diesel).
The drive home was uneventful, save for a stop by the Polizei (I had the four-ways on...).
Upon pulling into the driveway of my humble home, the van erupted in the sound of applause.
We made it! _________________ 1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat! |
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djkeev Samba Moderator
Joined: September 30, 2007 Posts: 32598 Location: Reading Pennsylvania
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Syncro Jael Samba Member
Joined: December 19, 2013 Posts: 2204 Location: Utah
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Posted: Sun Mar 06, 2016 4:23 pm Post subject: Re: Another Broken Gear Shifter! |
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We had one break also. A pair of vise grips also got us home. The shifter has an inherent weak spot due to the design.
I have now replaced it with a BIG SHOT shifter.
No worries anymore.
http://rsfabparts.com/index.php/product/big-shot-vanagon-shifter/
_________________ 1987 Syncro Westfalia Hightop - NAHT
Subaru EJ25 Forged Frankenmotor, Triple Knob.
Jael = (Mountain Goat) |
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IdahoDoug Samba Member
Joined: June 12, 2010 Posts: 10248 Location: N. Idaho
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Posted: Sun Mar 06, 2016 10:58 pm Post subject: Re: Another Broken Gear Shifter! |
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Nice - good field fix, man! In the tradition of motorists everywhere. _________________ 1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader |
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syncrodoka Samba Member
Joined: December 27, 2005 Posts: 12005 Location: Santa Cruz, CA
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Posted: Sun Mar 06, 2016 11:38 pm Post subject: Re: Another Broken Gear Shifter! |
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Syncro Jael wrote: |
We had one break also. A pair of vise grips also got us home. The shifter has an inherent weak spot due to the design.
I have now replaced it with a BIG SHOT shifter.
No worries anymore.
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I hope they got the kinks worked out. http://www.thesamba.com/vw/forum/viewtopic.php?t=645384 |
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JoshG Samba Member
Joined: March 16, 2005 Posts: 189 Location: Boston, MA
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Posted: Tue Mar 08, 2016 4:06 pm Post subject: Re: Another Broken Gear Shifter! |
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And another:
Busted mine today. Good thing I drive around with some tools in the car otherwise it would have been a call in to AAA.
Now what?
Are folks liking their Big Shots?
Track down a used one (I imagine these are not available new). |
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syncrodoka Samba Member
Joined: December 27, 2005 Posts: 12005 Location: Santa Cruz, CA
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Posted: Tue Mar 08, 2016 4:41 pm Post subject: Re: Another Broken Gear Shifter! |
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I have heard of people jamming a metal rod into the shifter hole for more rigidity then align the broken pieces and weld it all back together to fix them. |
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levi Samba Member
Joined: February 11, 2005 Posts: 5522 Location: Las Vegas
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Posted: Tue Mar 08, 2016 7:27 pm Post subject: Re: Another Broken Gear Shifter! |
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Looks like a good anti theft modification. _________________ One of these days I'm gonna settle down,
but till I do I won't be hangin round.
Going down that long lonesome highway,
gonna see life my way
https://youtu.be/cSrL0BXsO40 |
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Californio Samba Member
Joined: May 17, 2007 Posts: 1305
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Posted: Fri May 06, 2016 3:24 pm Post subject: Re: Another Broken Gear Shifter! |
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Mine broke last week and I cut the head off a 5/16 x 4 1/2" bolt, then welded it in first one side, then the other. Hardest part was keeping the carpet from frying...I did it in place as was pressed for time...it did melt part of the plastic ring. So far so good and actually feels a lot stouter than the original.
Kind of disconcerting when it falls off in your hand. |
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goffoz Samba Member
Joined: May 09, 2007 Posts: 1486
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Posted: Fri May 06, 2016 9:13 pm Post subject: Re: Another Broken Gear Shifter! |
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What are You guys doing to break this rod 25mm above the pivot???
I would expect the rod to break at the pin(weakest point)
I have a sticky 1 2 shift that I gentle thru on cold mornings( till I get it dialed)
What did you do to break a 9/16th shaft? |
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alaskadan Samba Member
Joined: January 09, 2013 Posts: 1857 Location: anchor pt. alaska
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Posted: Sat May 07, 2016 6:59 am Post subject: Re: Another Broken Gear Shifter! |
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Its hollow. Mine got bent by a tire shop monkey two weeks ago. To the point where i could change the radio station with it . The bend was right where the locking collar is. There is a detent for a set screw that's in the collar. There was a crack forming from the detent. I finished cutting it and found a solid steel rod to fit inside and welded it back together. Mine too feels better than before. |
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Californio Samba Member
Joined: May 17, 2007 Posts: 1305
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Posted: Sat May 07, 2016 12:19 pm Post subject: Re: Another Broken Gear Shifter! |
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I think the problem is with metal fatigue after 395K miles (in my case) and 30 years. How many shifts is that again? Each with a slight stress on the tube? |
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iheartstrangers Samba Member
Joined: May 19, 2010 Posts: 47 Location: Portland, Maine
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Posted: Fri Aug 12, 2016 7:09 pm Post subject: Re: Another Broken Gear Shifter! |
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Look at what happened to me tonight.
I've put about 200 miles on my 1984 Vanagon. I'm being initiated rather aggressively, but keeping a smile on my face.
Insert metal and weld. Is that the answer? Just out of curiosity, given that I don't weld, what should I expect to pay someone to do this? _________________ --
My name is Joshua and I am just getting started with an '84 Adventurewagen |
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syncrodoka Samba Member
Joined: December 27, 2005 Posts: 12005 Location: Santa Cruz, CA
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Posted: Fri Aug 12, 2016 7:39 pm Post subject: Re: Another Broken Gear Shifter! |
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iheartstrangers wrote: |
Insert metal and weld. Is that the answer? Just out of curiosity, given that I don't weld, what should I expect to pay someone to do this? |
12 packs go a long way with welders usually. |
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iheartstrangers Samba Member
Joined: May 19, 2010 Posts: 47 Location: Portland, Maine
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Posted: Fri Aug 12, 2016 7:40 pm Post subject: Re: Another Broken Gear Shifter! |
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Duly noted. _________________ --
My name is Joshua and I am just getting started with an '84 Adventurewagen |
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alaskadan Samba Member
Joined: January 09, 2013 Posts: 1857 Location: anchor pt. alaska
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Posted: Sat Aug 13, 2016 7:22 am Post subject: Re: Another Broken Gear Shifter! |
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I made sure to measure right where that detent was before it dissapeared under a weld. As well as scribed a line up the two pcs so that the lower pc wasnt rotated at all before welding. |
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iheartstrangers Samba Member
Joined: May 19, 2010 Posts: 47 Location: Portland, Maine
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Posted: Sat Aug 13, 2016 7:26 am Post subject: Re: Another Broken Gear Shifter! |
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Would you mind explaining this a little more? What happens if it is done incorrectly? I am not looking to do it incorrectly, just trying to understand what I am getting involved with.
While I am in the process, I am looking to change these parts - http://www.gowesty.com/product-details.php?id=24025 - is this a good idea?
Thanks! _________________ --
My name is Joshua and I am just getting started with an '84 Adventurewagen |
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scottbott Samba Member
Joined: June 02, 2010 Posts: 83 Location: essex,uk
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Posted: Sat Aug 13, 2016 11:32 am Post subject: Re: Another Broken Gear Shifter! |
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mine snapped a couple of weeks ago in EXACTLY the same place as yours,I bought a replacement from Brickwerks,it is a solid bar,expensive at £190 it will never snap again |
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iheartstrangers Samba Member
Joined: May 19, 2010 Posts: 47 Location: Portland, Maine
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Posted: Sat Aug 13, 2016 3:24 pm Post subject: Re: Another Broken Gear Shifter! |
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I disassembled mine today and will now seek out a welder. I am trying to do everything on a limited budget while still seeking for it to be quality. I'll have more info as I progress.
Thanks! _________________ --
My name is Joshua and I am just getting started with an '84 Adventurewagen |
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alaskadan Samba Member
Joined: January 09, 2013 Posts: 1857 Location: anchor pt. alaska
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Posted: Sat Aug 13, 2016 4:13 pm Post subject: Re: Another Broken Gear Shifter! |
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After you get it welded you will need to file or grind and dress the rod back to a smooth surface again. Then you will likely need to re drill the detent for the set screw on the collar. The collar needs to be back in the same spot. So just measure from the bottom end somewhere to know where that is. Scribing a line on the two pcs could just be a line with a sharpie marker. That is for the welder to align the two pcs so they dont get welded together 90 degrees off or 10 degrees off or you get the picture. |
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