Shifter rebuild kit doesn't match shifter
 

Hey guys, this is more of a transmission question rather than an engine question, but I don't have anywhere else to put it so w/e

I got my 5X racing shifter rebuild kit for my 2002 NB (5-Speed) and I got started on it, the tabbed wave washer doesn't fit over my shift lever. I've tried a bunch of things, but I can't get it to work. It's just a hair too small. The original tabbed wave washer fits perfectly over my shift lever.

I did notice that my shift lever has a much more pronounced lip at the bottom compared to the photos on the instructions from 5X racing. Do I possibly have a non-OEM shifter or some revised shifter design?

Additionally, my lower boot had a circular metal disc with a rubber boot attached, whereas the 5X kit came with a small, almost polygonal boot. I also cannot slide the boot over the shift lever.

What's goin' on here?!

Pictures?

Would have been a good idea to take some before I left the shop.

I'll pass by today and grab some pics.

I recently picked up a 6 speed, and had the same issue with the stock shifter on it. The shifter had a very pronounced flare at the bottom, and the spring clips and plastic bushings would not clear it. I was going to give it a quick pass on the grinder, but said screw it since it's getting an MR shifter after the holidays. The boot went over with a little silicone spray lube.

Just grind down the flare a bit so the parts clear.

So I'm going to the shop now, but I'm pulling some screenshots from the instructions available from the product page:


https://5xracing.com/i-18896895-5x-r...zda-miata.html

https://cimg2.ibsrv.net/gimg/www.mia...0fb1be80e9.png



In this instance, you can see that the lip is quite small and the washer goes over it, even with the instructions stating that it's a tight fit.


HOWEVER, some googling revealed this PDF
http://5xracing.com/attachment/117271-.pdf


Which has this image

https://cimg5.ibsrv.net/gimg/www.mia...a0c972b0b9.png




THIS is the shifter that I have. Looks like like that.

At the top of these instructions is the following line:

As performed and authored by John Adamczyk of 5X Racing on a 1999 Mazda Miata (5X
Racing Project Streetfighter) with a gen1 6-speed transmission


Does this mean that I have a FIVE-speed transmission with a SIX-speed shifter?!

I wouldn't put a lot of stock in that. Mine is an NB2 6 speed and has the same pronounced flare as the 2nd picture.

Does yours have one or two slots on the shifter pivot ball?

Just grind the lip till the parts fit; you had the right idea.

Two slots

So I decided to just re-use my old wave washer. It fit perfectly and still seems to have some 'spring' to it, so it should serve it's purpose just fine. I may add a small shim above it to add a little more pressure.

So weird that this happened.

I'll add a data point here- My 6 speed shifter definitely has that flare, and I recall the wave washer being a PITA to get on there. It's been a quite a few years now, but I do recall that the washer WILL fit, but you have to find some creative way to flatten it out as you slip it over the flare. The effective inner diameter of the wave washer is reduced in it's static wave shape/form. Once you flatten it, it will increase in diameter just enough to clear the flare.

Edit: That was with all stock parts

IIRC, only the 6 speed shifters have both slots, but don't quote me on it. Assuming it's a factory shifter.

Oddly enough, the (presumably) stock wave washer that came off the car was a hair wider in diameter and slipped over the lip with ease. EASE! Didn't even have to try, you just drop it on there and it does it's thing.

It's possible that at some point maybe they started using six-speed shifters in five-speed cars to save money? My shifter ball has two slots that slide into two dowel pins.

SPEAKING OF THE DOWEL PIN, I couldn't do the vice grip and spacer thing they recommended, so I just used a 6" extension, placed it on the dowel pin, and whacked the other end (gently) with a 3-pound hammer. When I was done, I just whacked the other end flush with the hammer (gently). Worked like a charm.

Pulled apart an NB 5sp that had the double slot shifter ball. Not documented well, but its a thing. Was out of 99 if memory serves.