BigMouse

We've all seen this before:
<img src="http://twigmouse.ipupdater.com/miscpics/listpics.asp?a=dl&ID=2706">

You know how it goes. Your shifter housing gets worn out the shift lever pulls up out of it's socket and you struggle to push it back in so that I can get moving again while the guy behind you is honking because you can't get your car into gear at the light.

There are a few options to fix it:
Buy the housing new ($$$)
Find a B3/B4 in a wrecking yard (hard to find in my area. I'm assuming that the B4 shifter is the same design, but I've never worked on one)

Here's what I did:

80's and 90's are hard to find in my wrecking yards, but every one has at least a couple 4000's. Take apart the shifter housing on one of those and grab this piece:
<img src="http://twigmouse.ipupdater.com/miscpics/listpics.asp?a=dl&ID=2711">

If you compare the 4k shifter housing with the kind we're used to, you'll see that the 4k housing is missing the toothed segments. These are required on our cars because the housing is all one bonded piece. The ball spreads those teeth when it is installed (or removed). These teeth are the weak point. The 4k design is split. The rubber surround stretches a bit to allow the ball to be installed/removed, then the whole bit is installed in the metal housing which holds it all together. A better design in my opinion.

<b>Here's how to install the 4k shifter housing into your B3/B4.</b>

Remove your shifter housing and drill out the spot welds holding the retainer to the bottom, as shown:
<img src="http://twigmouse.ipupdater.com/miscpics/listpics.asp?a=dl&ID=2707">

On the housing I was working on, not only had the teeth broken, but the rubber had separated as well:
<img src="http://twigmouse.ipupdater.com/miscpics/listpics.asp?a=dl&ID=2708">

This made the next step easier. If your rubber has not separated, it might help to cut the plastic piece out before continuing. Using a propane torch, apply some heat to a spot on the outside and use a screwdriver to get under the rubber. Once you've got it disbonded from that spot, use pliers and heat to work your way around the circumference, removing it a bit at a time. Not much heat is required to get it to come undone. Also, remove the little pads from the top side so you don't burn them.
<img src="http://twigmouse.ipupdater.com/miscpics/listpics.asp?a=dl&ID=2709">
<img src="http://twigmouse.ipupdater.com/miscpics/listpics.asp?a=dl&ID=2710">

Remove the little plastic piece from the outside of the 4k shifter joint and prepare to install it into your housing.
<img src="http://twigmouse.ipupdater.com/miscpics/listpics.asp?a=dl&ID=2712">

This picture shows the orientation of the 4k joint in relation to your housing:
<img src="http://twigmouse.ipupdater.com/miscpics/listpics.asp?a=dl&ID=2713">

Insert the ball of the shifter through the top of the mount and mate it to the 4k joint underneath. Once the ball is inside, push the whole assembly up into the housing. You should end up with this:
<img src="http://twigmouse.ipupdater.com/miscpics/listpics.asp?a=dl&ID=2716">

Line up the retainer with the holes you drilled earlier and clamp it. Weld the retainer back in place. If you don't have a welder, make sure that you drill the holes all the way through and use rivets or small nuts/bolts to hold it together.
<img src="http://twigmouse.ipupdater.com/miscpics/listpics.asp?a=dl&ID=2717">

Reinstall the little rubber pads, lube the ball with some silicone, and you're ready to install.
<img src="http://twigmouse.ipupdater.com/miscpics/listpics.asp?a=dl&ID=2718">

Pretty, no?
<img src="http://twigmouse.ipupdater.com/miscpics/listpics.asp?a=dl&ID=2719">

Considering that the 4k's are quite a bit older than our cars, and I've yet to come across a broke shifter housing/joint, I'd say that this should last a good long time.

The wrecking yard didn't even charge me for the joint. Just the $2 admission for my local self-serve yard.

red90q

Nice write up. Should be in the tech article section