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Old 01-05-2018, 10:45 PM   #1 (permalink)
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Default Gear Shift Jammed

The gear shift lever on my 1981 Sierra SJ410 has jammed in 2nd gear. A little east-west movement but no north-south.
Will take the top off the gearbox when I have the time next week and see what is going on.
I suspect one of the selector rods has jammed. Maybe a spring loaded indent ball has broken?
Any other suggestions?
Cheers
John
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Old 01-13-2018, 06:36 AM   #2 (permalink)
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Default SHifter

Bolt that secures the shifter is probably sheared off and wedged in one of the gear slots, this should be a cheap fix. Many online sites sell a whole kit to replace all the accessories. Keep us posted if you figure it out.
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Old 01-16-2018, 08:45 PM   #3 (permalink)
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Thanks for the comment. Will get to the gear box next week as having a busy time at the moment. Hopefully I can fix things with out removing the whole gearbox
Also picked up a second hand gearbox for free, but not sure of the condition. At least it may be good for some spare parts.
Cheers
John
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Old 01-31-2018, 09:52 PM   #4 (permalink)
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Finally found time to take the top off the gearbox. All came apart easily. 4 bolts hold down the rubber boot on the transmission tunnel. After removing this and another boot at the base of the gear stick, three more bolts secure a retaining ring on the turret on top of the gear box. Removing the retaining ring allows the gear stick to be pulled out of the box.
This immediately showed the problem. The ball on the bottom of the stick sits in a plastic cup inside the turret. This cup had crumbled away with age, allowing the stick too much free play and causing the end of the stick to jam in the three selector rods that shift the gears.
Using a vacuum cleaner, I sucked up all the broken bits of plastic cup to prevent them falling into the box. Being a weekend, I could not get to the Suzuki parts store for a new cup,(if they have one for a 1981 Suzi!) so found some large rubber washers in my plumbing parts box that substituted well for the cup. After applying a little grease, every thing went back together and works well. Nice smooth shifts.
I will chase up the proper part, but meanwhile the rubber washers are doing fine.
Cheeers
John
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Old 01-31-2018, 11:28 PM   #5 (permalink)
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That is terrific!
congrats.

A little resourcefulness to get you by in a pinch.

Please show us a picture so if we ever get in a bad spot and need a temporary way around the problem we would have your solution to help us out.

Don

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Old 02-03-2018, 01:34 AM   #6 (permalink)
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Default Gear Shift Jammed

Hi Don
Attached is a photo of the turret from a 1981 Sierra gearbox. You can see the crumbling orange/brown plastic cup that the ball on the bottom of the gear stick sits into. The pin screwed in from the side of the turret fits into a slot in the ball and stops the gear stick rotating as well as acting as a left/right pivot.
The two spring loaded plungers visible hold the gear stick in the neutral position.
This turret is from a spare gear box I have. I thought I would just swap over the turrets, but this one is nearly as bad as the one on the car.

I placed a leather washer, about 1 3/8 inch diameter and 1/8 inch thick in the bottom of the turret after cleaning out the old plastic, and a rubber washer about the same dimensions on top of the ball on the gear stick. There is a wavey steel spring washer (original part) that goes on top of that to put downward pressure on the ball.The whole lot is held in place by the retaining plate with three bolts.

Went to the Suzuki dealer and after a lot of searching they found a parts diagram for a 1981 Sierra. Unfortunately the plastic cup is not available as a separate part, only the turret complete for $150 with freight extra, and then only available from Japan.
I said no thanks, the 50 cent plumbing washers seem to work fine.

I have looked at later year Sierras, and some have an aluminium cup which is part of the turret casting, so obviously this is a known problem.

If my washer solution does not hold up, I will try turning up a new cup on my lathe using a white PVC irrigation fitting as a starting point.

Cheers
John
Attached Thumbnails
Gear Shift Jammed-gearbox-turret.jpg  

Last edited by johnfromperth; 02-03-2018 at 01:52 AM.
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