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.

[raynekat]

That die grinder made quick work out of opening up the opening in the bulkhead.
Only took a couple of minutes.

Making good progress, almost there.



Made sure not to cut away too much metal close to this tube that is welded to the bulkhead.



This is the finished hole with the shifter in the R-1st plane.
I noticed a small "V" of metal at the top of the hole.
Although it wasn't touching the shift rod, I didn't want to have to come back if the rod did start hitting the top of the opening.



Just touched up the point of the "V" with a hand file enough to smooth it out.
No way the top of the shift rod will hit any part of top of the opening in the bulkhead.





All that's left to do now is vacuum out the the inside of the tunnel of all the metal shavings and re-fit the access panel I cut out.
Then replace the interior that was removed earlier.

Man....it's so nice for that annoying scraping/squeaking to be gone.
Total cost was a couple of days fiddling a few hours here and there and the $10 cutting blade from Harbor Freight.
Another job knocked off of the "post build" punch list.
Just a few thousand more to go.....and I'll be there.
Ha
(IMG:style_emoticons/default/smilie_pokal.gif)

We've got some dry weather this coming week in Portland, so I'll get the car out and enjoy the silent shifting. (IMG:style_emoticons/default/aktion035.gif)