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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.
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 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.
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.
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
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.
12-20-2019, 09:42 PM
Shifter rebuild kit doesn't match shifter
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