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.

[gereed75]

My original six with side shifter did this. From memory it went away once I refurbished the shifter with a Weltmiester short shifter and Tangerine firewall bushing.

Never realized this clearance hole was different in early cars vs side shifters and how lucky I was that this worked itself out.

Now wondering what will happen as stuff wears. At least I will know what it is

The other thought I had was that you could maybe cut the shift rod in this area and weld a smaller diameter section into it at this area. Lotsa work, but maybe no more than accessing the tunnel to clearance the hole.

[ChrisFoley]

Never realized this clearance hole was different in early cars vs side shifters and how lucky I was that this worked itself out.

I'm not sure the hole is any different. The early shift rod was a larger diameter but was supported by bushings at both ends so it only rotated and moved fore/aft. The sideshift rod moves left and right at the shift lever so requires more room around it.

[raynekat]

The sideshift rod moves left and right at the shift lever so requires more room around it.

This is definitely the issue.
When you move the shifter left into the R-1st plane, the bottom of the shifter and the attached shift rods moves in the opposite direction to the right...and quite bit right. Enough obviously to hit the passenger side of that hole in the bulkhead or hoop as Cary calls them.
Even in the neutral plane you can hear the shift rod bang up against the inside of the hole in the hoop.
Then when you move into R or 1st, you hear the big scrape.

I'll definitely get in there with my small flashlight and mirror from both ends (through the shifter hole and also the small access cover back by the rear fire wall.
I'll measure from both directions to find exactly where the bulkhead/hoop is located.
My access hatch that I will cut needs to be located aft of this just a bit.
I'll also look at where everything is located to make sure I don't mistakenly cut into something by accident.