In a previous post I mentioned getting the steering column intermediate shaft from a PAS Montego or Maestro. That part will provide two DIFFERENT U-J sizes.
I discovered last Saturday that the NON-PAS intermediate shaft fitted to these cars has two U-Js
of the same size and both are a close fit on the stubby input shaft on the PG1 gearbox. So with the NON-pas shafts you get TWO suitable U-Js
for the price of one.. My kind of deal...
The splines in the U-J's clamps need to be ground away with a stone in an electric drill to enable them to be a perfect fit on that input shaft.
I'm in the process of doing a batch of this worthwhile mod for the 620ti and if as I suspect the gear linkage between the gear lever and the gearbox is the same item in the Diesel 620, next time I see one of those in the local breakers I'll get it or them. There has been three Diesel 620s in the local yards this year and I did not bother to get the shafts. Wish I had now.
To make the job a perfect one using these far stronger U-Js
on the 620ti shafts, a small steel crank needs to be fabricated and welded with the correct offset to provide firm and balanced leverage for the gear seletion action. I shall take pictures as I work but my Minolta Digital has lost it's screen and only takes black blanks now. I'll borrow my son's Nikon when I get a chance.
These steering column intermediate shafts are far easier to remove from Montegos and Maestros than U-Js
from R400s etc.
More info to follow when I get the time...
EDIT @ 00:27
Meantime, here's a picture of a similar arrangement on a R220. I believe the U-J used here is a Ford item (query?) but the picture shows the CRANK which needs to be fabricated and welded to provide sufficient control and leverage for the gear change action.