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.

[raynekat]

So how'd we do?

Here's the money shot.



Tomorrow I will clearance some of the area I've got highlighted in the red.
Just enough so that the rod doesn't scrape across this bulkhead opening when in the R-1st shift plane.

This view gives you a good idea where all the cables and tubes are inside the tunnel.
None were directly above the shift rod area (which I knew already by looking in from the shifter opening) and everything is well to the passenger side of the opening or below it.
I'll push the shift rod as far to the driver side as possible to give me clearance I need.
Should be able to make the opening bigger with the shift rod in place.

I'll be using these bad boys to do that.
And they are a bit more dangerous to be sure.
Luckily the cutter will be in the tunnel while me and my body are outside the tunnel. (IMG:style_emoticons/default/wink.gif)

The rest of the story with pics tomorrow.....