Question for the gear shift experts: big scrap in R-1st shift plane on side shifter Options

[raynekat]

I've got a 71 914-4 that I converted to a 914-6.
The problem is a very loud annoying squeak when I'm in the R-1st plane.
Something is really scraping badly.
Pulled the shifter which looks to have been changed out from an early shifter to a later shifter.
Greased it very well and that didn't seem to help.

So I looked a bit deeper and put a flashlight in the tunnel where the shifter sits pointing backwards.
Using a small mirror about 6-9" rearward, I see that the shift rod goes through a circular opening in a small bulkhead that is welded into the tunnel.

Looks like the scraping/squeaking is when the rod is hitting the edge of the circular opening in the bulkhead in the R-1st plane.
If you don't pull the lever all the way to the left, then you don't hear the scrape.

Is this typical of a side shifter conversion for an early 914?
Am I shifting incorrectly by pulling the lever hard to the left for the R-1st plane?
Does that bulkhead need to be removed by opening up the shift tunnel from above?

Any thoughts or ideas are welcome.
Thanks in advance.

[BillC]

As part of the conversion to a side-shift tranny, that bulkhead you found needs to have the opening enlarged. Otherwise, as you've discovered, the shift rod will rub against it and make a nasty noise, if it even works at all.

At this point, the most common choices are either live with the noise or pull the shift rod out and open up that hole in the bulkhead. I supposed if you really wanted, you could make a custom-offset shift rod that would clear the bulkhead, but I don't know how much work that would be.

I did a side-shift conversion for a friend a couple of years ago, and I can tell you from first-hand experience that that bulkhead can be a royal pain to get to without cutting an access hole.

[raynekat]

As part of the conversion to a side-shift tranny, that bulkhead you found needs to have the opening enlarged. Otherwise, as you've discovered, the shift rod will rub against it and make a nasty noise, if it even works at all.

At this point, the most common choices are either live with the noise or pull the shift rod out and open up that hole in the bulkhead. I supposed if you really wanted, you could make a custom-offset shift rod that would clear the bulkhead, but I don't know how much work that would be.

I did a side-shift conversion for a friend a couple of years ago, and I can tell you from first-hand experience that that bulkhead can be a royal pain to get to without cutting an access hole.

Thanks BillC.
That aligns with what I am seeing.
I think you are right that the opening in the bulkhead needs to be opened up more or completely removed.
I see a small tube welded to the bulkhead as it passes by bulkhead, so maybe removing the bulkhead will bring other challenges....what does that small tube get welded too now?
Etc, etc.

I thought perhaps I could make an adjustment as to how the shift rod is "clocked" into the shift housing by rotating some splines clockwise or counterclockwise but doesn't seem to be doing much good. Just driving me crazy is all.

Anyone else out there with similar experiences or sage advice at this point?

Think I'm going to have to cut an access panel into the top of the tunnel where the bulkhead resides and get busy making modifications in that area.