Sloppy PG1 Gear Linkage - How To fix it! - Page 3 - MG-Rover.org Forums
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post #41 of 224 (permalink) Old 13-11-2006, 15:34 Thread Starter
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Originally Posted by doug View Post
sorry bud, I just havn't had time, family health prob's, daughters clio hgf, etc,etc,...., doug.
np - any time. - I didnt realise Clios used rover 1.8 engines? lol
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post #42 of 224 (permalink) Old 14-11-2006, 23:20
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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.

http://img.photobucket.com/albums/v3...l/coupe001.jpg

Apparently ... in a parallel universe MGJohn drives .........A.......

B>>M>>W ....

Arrrrrggghhhhh......... ......

Last edited by MGJohn; 14-11-2006 at 23:27.
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post #43 of 224 (permalink) Old 14-11-2006, 23:39
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that the self same uj i have on mine john, R200 bubble is where i got mine
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post #44 of 224 (permalink) Old 15-11-2006, 00:36
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yep, interesting and something else to look into.... I always go by the rule of measure TWICE cut ONCE rule o'thumb.... or in this case measure TWICE.... that aint going to work!... yet!, thanks, doug.
Measure twice, cut once, discard and repeat
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post #45 of 224 (permalink) Old 15-11-2006, 07:24 Thread Starter
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offset

Hi Guys
MGJohn

Are yu sure yu need the offset - on my 220Turbo I didnt put any offset and it works fine. My reason for asking is that anyone can fit the UJ onto the gear select shaft - but making offsets is possibly beyond some people. Maybe a list of cars which NEED to have the offset might be useful?

You say you are "making a batch" - are you going to offer this as an "upgrade/repair" purchase?

Richard

Last edited by The Mad Hat Man; 15-11-2006 at 08:04.
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post #46 of 224 (permalink) Old 15-11-2006, 15:24
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second the one without the cam design , although mine is quite heavy but i put that down to the short stick giving lack of leverage
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post #47 of 224 (permalink) Old 01-01-2007, 11:44
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Quote:
Originally Posted by Si View Post
second the one without the cam design , although mine is quite heavy but i put that down to the short stick giving lack of leverage
Just spotted these responses ~ that offset appears built in on most of the OE gear lever shafts I've examined. Although only a small offset, it provides sufficient leverage thus reducing the 'quite heavy' effort needed by Si.

Try selecting gears with a gearbox OFF THE CAR using a short rod placed into the roll pin hole in the input shaft. Selecting all six gears requires considerable twisting effort and lack of leverage provided by that slight offset could make all the difference.

I always do this 'try selecting gears' test on PG1 gearboxes I've rebuilt with new bearings etc to avoid discovering selection problems once it's fitted to the car as others have sometimes discovered much to their chagrin.

Apparently ... in a parallel universe MGJohn drives .........A.......

B>>M>>W ....

Arrrrrggghhhhh......... ......
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post #48 of 224 (permalink) Old 01-01-2007, 12:21 Thread Starter
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On mine the effort is, well, effortless. Cant comment on anyone elses tho.
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post #49 of 224 (permalink) Old 01-01-2007, 13:05
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On mine the effort is, well, effortless. Cant comment on anyone elses tho.
That's nice to know. There's a common theme here: R200s. Maybe that's the difference.

Those I've recent experience of are the larger 600 and 800 PG1 fitted cars which have a distinct offset at the gearbox end of the gear u-j shaft. Although I changed the gearbox twice on R220 turbos, can't remember the design of their shafts.

Apparently ... in a parallel universe MGJohn drives .........A.......

B>>M>>W ....

Arrrrrggghhhhh......... ......
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post #50 of 224 (permalink) Old 01-01-2007, 13:38 Thread Starter
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As I said - I only experience on mine - which is a 220 Turbo. Here are the piccies of the bit that was cut off. You can clearly see the offset, but it appears to be easily taken up by the angle change of the gear rod. It might be obvious, but the rat-eaten bit is the part that was attached to the rod before hacksawing off.
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post #51 of 224 (permalink) Old 01-01-2007, 13:55
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Originally Posted by The Mad Hat Man View Post
As I said - I only experience on mine - which is a 220 Turbo. Here are the piccies of the bit that was cut off. You can clearly see the offset, but it appears to be easily taken up by the angle change of the gear rod. It might be obvious, but the rat-eaten bit is the part that was attached to the rod before hacksawing off.
That is very interesting. Compare that offset (minimal) to that on this 620ti equivalent for instance:



What is NOT obvious from my picture is the amount of offset. That's because of the angle the picture was taken at. The offset is actually rather more but I don't have an end on shot to illustrate it. Even so, my picture clearly shows considerable offset.

Apparently ... in a parallel universe MGJohn drives .........A.......

B>>M>>W ....

Arrrrrggghhhhh......... ......
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post #52 of 224 (permalink) Old 01-01-2007, 14:02 Thread Starter
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The offset on the 220 is about 1/2" in one plane and about 1/8" in the other (12mm & 3mm) - considerably less than the 620
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post #53 of 224 (permalink) Old 08-01-2007, 20:25
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Found this thread at last, great news as my gear change on my 220 SDi diesel is very sloppy and the gearstick sometimes rattles.
Will be having a go at this mod as soon as i get myself the correct "steering column Universal Joint" - But article says from a 416 Rover, which model/year please or can a 200 bubble be used for donor part ?

Or a part number to buy new if cheap ?

Cheers Ian

Last edited by 220ttblue; 08-01-2007 at 21:16. Reason: Added text
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post #54 of 224 (permalink) Old 12-01-2007, 19:02 Thread Starter
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Gear linkage

Hi I believe that the gearbox selector shaft and the gear selector road are both 14mm diameter, so any uj that fits these sizes should be OK. If someone can confirm these sizes, I will update the procedure.
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post #55 of 224 (permalink) Old 13-01-2007, 15:16
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Thanks mad hat, si has been a help as well.
Off to the scrappers on Monday, they`ve got 200 and 400 bubbles in so will try and get a couple of the steering column UJ`s

Will be trying the mod next saturday, will report back and let you know if they are ok from the donor cars

Cheers Ian
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post #56 of 224 (permalink) Old 05-02-2007, 15:50
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Finally got round to doing the UJ mod and it worked a treat. Gearshift is now super smooth with no rattles.

Just to let you know that when i went down to my local scrappers the UJ from the bottom of the steering column is the same on Bubble 200 rovers and "bubble" 400 Rovers.

Thanks for all the help and advice

Ian
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post #57 of 224 (permalink) Old 05-02-2007, 19:54
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glad to see another person getting the rewards for this little cheep assed mod

Si
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post #58 of 224 (permalink) Old 21-02-2007, 18:09
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got myself a uj coming, 11 delivered saves me taking one off at a scappy

and i will be doing this mod shortly

i have a 400SD with 181 thousand on the clock so it needs it
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post #59 of 224 (permalink) Old 03-05-2007, 13:29
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Hey, you know the walkthrough, it has no pictures, can somebody get some please?

I want to do this as well as shorten the shifter and extend it at the bottom.

I need a UJ and what else?
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post #60 of 224 (permalink) Old 18-05-2007, 11:31
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Excellent mod, did it last night along with the two polyurethane bushes on the stabiliser linkage.
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