Shifter slack and positioning fix
I just got this 91 JL hardtop model 3 days ago. I noticed a bunch of slack in the shift patern and a problem with my fifth gear missing and grinding going in. It did not do this on my test run. Another thing I could not stand, was the fact the the shift lever hit the bottom of my dash in 1,3 and 5. I have no doubt, this added to my problems.
So, dredding my worst case scenerio, (shift linkage-not knowing anything about Zuki's) I pulled it up on ramps to get a look at my mess. To my suprise, NO LINKAGE!! WOOHOO!!
Anyway, long story short. OR LONGER ~ There is an eyeball socket on the lever. There is a groove in the rear of it. A bolt seats in that groove from the body. The bolt was backed out slightly. This gave it slack.
It also wollowed out my groove. It had two, very prominate wear spots on the sides on the short end of the lever shaft below the ball. I had to weld these areas solid and mill a new groove in the exact spot where the bolt gets seated. I then ground down the weld to flush and lightly polished up with a flap wheel.
Get a bucket of hot water. I also ground a groove half way through the shaft in the nape of the shaft's "elbow" as it is solid through and through. This allowed me to easily heat up that area with my propane crawfish boiler/burner.
Take care, as the shaft is a 2 piece assy. and has a rubber gromit between them. It will catch fire and melt away. So keep an eye on that. Blow it out, when it does.
When you get the area cherry hot, hammer on the grooved side to bend it closed. Not all the way, because you must squeeze a weld in there.
Next step: weld shut-dunk in water. Dry off.
Next I crimped the outer shaft section to the solid piece with a hammer and anvil. Make seal weld around it. This will leave a whole in your weld where the rubber gromit will smoke your weld out. Make sure you make your closure on this weld on the bottom, were you will not see it.
I then picked a spot 6 inches from the top of the lever, near the shifting ball. Heated and bend that at roughly a 45 angle (same as the first bend you made). Then primed and painted. Lever should look like a lazy or elongated "z".
One more problem I may have found. (Not sure, common sense tells me) Seems there should be approx. 1/4"-3/8" spacer washer or gromit that sits on top of the curved washer that gets sandwiched on top of the ball when the lever assy. sits in the top of the tranny and the retension bracket is in place. I don't know for sure, but the lever assembly did move up and down in the casing too much. (I thought).
I could not find a metal washer or spacer thick or large enough to go in there. So I shaped on from a thick piece of ridged polyfoam I had laying around.
Grease ball of shift lever before final assembly.
I can tell you that once I had things reassembled and tight, The shift patern is how it should be.
*Lever doesn't hit bottom of dash anymore.
Clears everything nicely. SMACK DAB IN THE MIDDLE!!
*No problems with fifth gear.....so far.
*Everything is stiff as it would have come from the factory, I presume.
As I drive it more I'll know for sure if this fixed my problem.
Sorry to bore you. Thanks for reading.