JWest Shift Kit Install Part 1: the transmission, WARNING: 5.5mb of images Options

[McMark]

Okay folks, here it is. The pictorial installation of the JWest Shift Kit. Everything went pretty smooth and the setup is real quality. We made a few Original Customs ((IMG:style_emoticons/default/av-943.gif)) to it.

Here is the shifter, ready for modification. Isn't it just begging to be upgraded? (IMG:style_emoticons/default/happy11.gif)


First we test fit.


Andy marks the holes.


See the marking?


Here they are...


Time out to install the shifter bushing. Grease up the cup.


Grease up the shifter ball.


Push the bushing onto the ball.


We drilled a hole in the bushing to let air escape. MUCH EASIER TO INSTALL!


Center punch the markings to keep the drill bit from wandering. Then pre-drill with a small drill bit. The center punch markings are too small for the large drill bit. So make the punches a bit bigger with the small drill (you don't need to go all the way through).


Center punches.


Start drilling! We used a letter P drill bit which was the Perfect size for a Porsche. (IMG:style_emoticons/default/av-943.gif)


Your markings need to be pretty accurate or use a larger drill bit. We had to elongate one hole slightly.


The bolts fit though great!


Start the bolts.


Then tighten with a wrench.


Test fit the shift rod through the stock shifter piece.


Here it is in place.


Custom #1: James supplies a bolt to hold things in place. Andy and I decided to grind a stock cone screw. For only one reason, it's more original. (IMG:style_emoticons/default/wink.gif) The bolt would work fine and doesn't use up an extra 15 minutes.


After grinding it threads all the way in and holds firm.


Remove the rod again and grease the bushings.


Custom #2: We decided to sacrifice Andy's old shifter cover and rivet the 'tube' on the other side of the new one.


We sealed it up with RTV.


And finally cleaned up the excess once it dried.


This is only the beginning:
Click here for part 2

[SirAndy]

a few comments ....

- the supplied instructions refer to parts (with numbers) in a diagram but no diagram was supplied as reference. (IMG:style_emoticons/default/blink.gif)

- the back hole in the shift cover was a bit off and had to be enlarged for the grey plastic piece to slide in. (IMG:style_emoticons/default/sawzall-smiley.gif)

- the bottom "access" hole for the screw that holds the shift-cupler was a bit off.
it was impossible to use the supplied 13mm bolt as you couldn't get a socket on it.
we used a ground down stock cone-screw instead. (IMG:style_emoticons/default/smash.gif)

- in the end, we decided *not* to use the supplied setup for the end-boot. the grey plastic piece that slides on the end of the shaft was too lose and when we put the boot on it, the boot would pull the grey plastic with it every time the shiftrod was moved backwards.
plus, it was impossible to get a good seal on the shift-cover, especially on the top part, near the outer clamp. (IMG:style_emoticons/default/dry.gif)

- there are three thin washers (or spacers?) that came with the kit that are not mentioned in the instructions. it was not obvious what they are for, so we didn't use them. (IMG:style_emoticons/default/confused24.gif)


as you can see in the pics above, we ended up cutting up my old shift-cover, using the old input piece, flipped it over and riveted (is that a word?) it onto the cover.
we omitted the grey plastic piece and mounted the end-boot the exact same way as the boot on the forward end.
that worked out great! (IMG:style_emoticons/default/smilie_pokal.gif)

then we went on to install the firewall bearing/bushing. more about that in part 2 ...

besides the few little glitches, the kit is going to be schweet!
(IMG:style_emoticons/default/thumb3d.gif) Andy

[JWest]

- the supplied instructions refer to parts (with numbers) in a diagram but no diagram was supplied as reference. (IMG:style_emoticons/default/blink.gif)

Yes, the diagram is not done yet, sorry.

- the back hole in the shift cover was a bit off and had to be enlarged for the grey plastic piece to slide in. (IMG:style_emoticons/default/sawzall-smiley.gif)

Each installation will put the rod support in a slightly different position. The cover will deform to allow rotation to line things up. Note that most cars do not have the cover hole lined up over the shift rod, and it is not impoartant as long as it clears. You were probably lining it up exactly on the front side since you had the advantage of doing it with the trans out.

- the bottom "access" hole for the screw that holds the shift-cupler was a bit off.
it was impossible to use the supplied 13mm bolt as you couldn't get a socket on it.
we used a ground down stock cone-screw instead. (IMG:style_emoticons/default/smash.gif)

This may be an issue with having the trans upside-down. The bolt should be accessible if you rotate the linkage away from the trans.

- in the end, we decided *not* to use the supplied setup for the end-boot. the grey plastic piece that slides on the end of the shaft was too lose and when we put the boot on it, the boot would pull the grey plastic with it every time the shiftrod was moved backwards.
plus, it was impossible to get a good seal on the shift-cover, especially on the top part, near the outer clamp. (IMG:style_emoticons/default/dry.gif)

I can increase the interference on that a little bit. The gray plastic part is supposed to be sealed to the boot with silicone - this would hold it in place better and seal the gaps that will be there due to casting and installation differences.

- there are three thin washers (or spacers?) that came with the kit that are not mentioned in the instructions. it was not obvious what they are for, so we didn't use them. (IMG:style_emoticons/default/confused24.gif)

The description was not in the version of instructions I sent you. Those are for shimming the support in case casting inconsistencies cause the shift rod to bind. It works without in most cases, but I included them since the castings are not all the same. The instructions have been updated.

as you can see in the pics above, we ended up cutting up my old shift-cover, using the old input piece, flipped it over and riveted (is that a word?) it onto the cover.
we omitted the grey plastic piece and mounted the end-boot the exact same way as the boot on the forward end.
that worked out great! (IMG:style_emoticons/default/smilie_pokal.gif)

That's nice - good work!

besides the few little glitches, the kit is going to be schweet!
(IMG:style_emoticons/default/thumb3d.gif) Andy

Thanks for the write-up and the feedback!