If the hinge pin locations in the gear shaft Universal Joint look like this:
Note elongated wear in hinge pin holes ......then your gear lever will be very sloppy and in an extreme case, gears 1,2,5 and reverse will be difficult to select. Those 3 or 4mm of wear 'play' will be much magnified at the gear lever in the car.
Here's few pictures of a simple modification I have now fitted to three 620ti which had sloppy gear levers ~ one so bad that the previous owner destroyed the wood effect surround because he had to move the lever so wide that it broke the trim.
First I cut off the worn U-J close to the end of the shaft:
Then using one of the TWO U-Js
from either end of a Montego or Maestro intermediate steering column shaft, weld that to the shaft end having first measured carefully the length needed and correct angle so that it will locate properly on the input shaft on the PG1 gearbox. Using these U-Js
eliminates the need to use those difficult to remove and sometimes fit the roll pins. By the way, the Non-PAS Maestros and Montegos will provide TWO suitable U-Js
, then PAS cars only one as their U-Js
are a larger size where it locates on the steering rack.
Close up of the U-J welded to the shaft:
A quick work over with the wire brush then a lick of paint:
Then fit to car:
Note: the relative angle of offset involved is 45 Degrees.
Having fitted this modified U-J linkage to three cars now I can confirm the improvement in the gear lever action is so good, it's no exaggeration to say better than new.