Intermediate lever problem
 

Just replaces the intermediate lever assembly with one I had laying around in attempt to tighten things up in the shifter. When I put it back together, it is forcing the shift bar upward and the top mount of the intermediate shaft assembly is touching the sheet metal...totally binds up. I'm thinking we are trying to install it in a wrong gear position, but I cannot determine what gear it is in when I turn the shaft. Anyone had this problem? You guys seem to always have the answer.

Barry

Here is the parts diagram.

http://forums.pelicanparts.com/uploa...1196763203.jpg

Mount it as shown. Pay close attention to the plastic block between rubber bush #21. This where most diy make mistakes.
Make sure the bolt #26 sits on the hole indentation in the tranny selector shaft.

Bazar01,

The plastic block you refer to, why is there no part number for it? In your experience, does this part wear and cause sloppy shifter or is it the intermediate lever-part 18? I am working back from the shift lever that has a new bottom plastic bushing and brass sleeve installed to compensate the hour glass shaft pin. Still too much left-right movement. If the intermediate lever does not wear, I guess the next purchase would be a new shift lever. Are the aftermarket shift levers preferred to the OEM?

Thanks,

John_AZ
1988 924S + 1987 924S

Yes, John, the intermediate lever is the whole assembly part #18.
The plastic part wears out causing a lot of side to side play.
I doubt if you can just get the plastic part.
Some diy just replace it a machined aluminum block.
I think I saw some machined aluminum blocks for sale on ebay.

Also make sure to blue loctite the bolt #26. They tend to loosen.
You'll get irritated driving away from home and you can't shift.

Thanks bazar01,

Another Q-Do you know if anyone has tried to sleeve the plastic block? Would it work/hold?

John_AZ

You can easily sleeve I think the smaller 10mm hole (31.6mm long x 12.7mmOD bushing). Still has lots of wall thickness.
But the 15mm hole will be a stretch. You can try a 19mm OD x 15mm ID x 32mm long bushing.

Thanks again bazar01,
Especially for the detailed measurements.

John_AZ