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Jon Weywadt
YaBB God
    
Posts: 1002

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« Reply #23 on: August 05, 2010, 10:07:44 pm » |
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The joy never stops.  Today I drove to my friend Jan and on the way there I thought the gear shift lever seemed loose. I thought it might be the teflon wrapping I put around the ball that had worn out. Alas, it turned out to be the sleve above the slot for the reverse lock-out pin, that had broken off. While ivestigating it closer, the spring pushed the lever completely out of the remaining piece. I removed the spring and tried to drive it, being careful not to use great force. But after a few shifts the pieces on either side of the slot, spread out and the shifter could not be used. I used a pair of pliers to squeze them back in place and placed a hose clamp around it, so it could not spread out again and to hold the lever in place. I made it home and removed the gear shift lever. the photos show the piece that broke off. After cleaning the pieces, I applied flux and brazed the pieces back together with silver. First I had wrapped the nylon ball im aluminium tape, because I knew it wouuld melt, no matter how careful I was. When cooled off I removed the aluminium tape and found that the nylon ball was mostly intact, though not completely round. So a bit of filing and sanding (the aluminium tape stuck in the nylon of course) I wrapped it in a new sheet of Teflon, applied grease to the pieces and assembled it all again. It now works "like new", well almost. 
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Jon Weywadt
YaBB God
    
Posts: 1002

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« Reply #25 on: August 15, 2010, 08:34:47 pm » |
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Jon (and others) this split gear lever on early models has always been fragile and prone to breaking and it is not necessary. --- The gearbox itself has no requirement for this detent selection.
Regarding your comment on another thread, about the wiring and the current through the ignition switch, the window motor currents do not go through the ignition switch. The ignition switch powers up the fourth relay on the board and the motors are powered from the relay. (other three relays are: 1 for dip, 1 for main, and 1 for aux. driving lights)
Roy
I was wondering about that when I replaced the second gear synchro this summer. It seemed that there was a reverse gear detent in the box, that should prevent you from going from 5th. straight to to reverse. However, I did not investigate it closely as I was busy looking for the pin and spring. They were not easy to hold in place during assembly and popped out 3 times before I got it.  About the ignition switch. I am relieved to hear that. Jan and I had measured the power consumed by the windows and the blower. We missed that the windows go through relays. However, the blower does not, and if I remember right, we measured it to appx 15 amps on step 3. As I wrote in another post it nearly caught on fire last sunday, so it will also go through relays as fast as I can make the mod. /Jon
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Matranaut par excellence 
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