My Gearshift Housing Disassembly/Reassembly
 

Beyond the normal vagueness of the shifter, my 5 speed had no resistance when pressed against the first/reverse lockout plate.

Here is my disassembly/reassembly in hopes it will be helpful to others.

The lockout plate, shift rod, and upper bushing were worn.

The lockout plate, thrust spring, and "top" bushing parts are shared with the 914.

***Be certain to wear gloves and eye protection when removing the springs - they are quite compressed and will launch from the housing when the tension is removed - I covered them with tape and used a gloved hand and rag to free them.

I welded some filler material into the worn shift rod groove and shaped it.

After the components were removed from the housing I removed the old paint and sprayed it with satin black.

After re-installation and a shift linkage adjustment things are much much better.



http://forums.pelicanparts.com/uploa...1562430629.jpg

In the vise
http://forums.pelicanparts.com/uploa...1562430685.jpg

After removing the e-clips from the pins, push the pins out *Wear eye protection and gloves the springs are under a great deal of tension - I also covered them with a rag while releasing the tension.
http://forums.pelicanparts.com/uploa...1562430793.jpg

Remove the lockout plate, lower bushing, thrust spring, and upper bushing.
http://forums.pelicanparts.com/uploa...1562430897.jpg

The components
http://forums.pelicanparts.com/uploa...1562430963.jpg

The upper bushing, thrust spring, and lockout plate are shared with the 914 - I disassembled a shifter from one of my 914 parts cars (73')
http://forums.pelicanparts.com/uploa...1562431001.jpg

Reassembly - rod, upper bushing, thrust spring, and lower bushing, then the lockout plate.
http://forums.pelicanparts.com/uploa...1562431146.jpg

Secured in a vise with vise grips holding the lockout plate in place
http://forums.pelicanparts.com/uploa...1562431300.jpg

Reinstall the springs - this part is frustrating, this method worked for me - *Remember the gloves and eye protection. Install the e-clips when the pins are in place.
http://forums.pelicanparts.com/uploa...1562431385.jpg

Back together
http://forums.pelicanparts.com/uploa...1562431473.jpg

Thanks for sharing!