In order to do this, the original shift pin needs to be modified to have the slot facing forward. The predominate method used by people was "heat and twist". Using a heat gun the plastic shift pin was heated up slowly and twisted 90 degrees so that the slot would be facing forward. Many folks have had success with this approach while others like me had varying degrees of success. From my experience (or lack of), using a heat gun presented a few issues and risks:
- deforming the shift pin or slot
- difficult to keep the shift pin straight
- burning the plastic shift pin to the point of weakening the part (this is what happened to me, the top portion of the shift pin actually broke off)
- the slot needed to be sanded to widen it bit vertically and horizontally
The method I used involved cutting the top portion of the shift pin off, then re-installing using a set screw. To me this method eliminated the risks I listed above. To me, it is easier and removes alot of the variables in terms of position of the slot. I cannot take 100% credit for this as there have been other members who have done this method before me. Like me they did it only after destroying their shift pin using the heat and twist method. I think you can save yourself some time and the hassle of having to make another shift pin like I did if you use this method.
Regardless of the method you use to do this mod, I have found there are a few critical things to consider when doing this in order to ensure success:
- the slot needs to be made "taller" by at least 2mm so file down the bottom of the slot
- the slot needs to be angled slightly to the left instead of exactly facing forward. If you look down directly at the shift pin you will see a metal sleeve in which the pin slides up and down in. On the sleeve are two notches/slots, one directly in front of the climate controls and one opposite. You can see that these notches/slots align themselves slightly angled left. I believe these notches are used as guides for the shift knob when it is installed so it makes sense to align the shift pin slot to these.
So here are the steps:
Tools - you will need a small hacksaw, a 1.0 and 1.5mm drill bit, M2x10mm set screw, M2x0,4 hand tap, a Dremel or some other small handheld drill you can easily control, small needles files or sand paper. Everything can be purchased from ebay. Aside from the Dremel all of these parts will cost less than $20.
Time: 1 hr
Step 1: Use your hacksaw to cut the shift pin right at the top of the metal shifter sleeve. I rested the blade right on top of the metal sleeve so that it acted as a guide to ensure a level cut. The plastic is very soft so this should not take more than 1-2 mins
Step 2: Use a file to smooth down the newly cut surface. Again, use the top part of the metal shifter sleeve as a guide to level the plastic surface.
Step 3: Drill and tap the top slotted portion. Try your best to drill on center and be as straight as possible. Since you are only drilling down a short distance, even if you are a little bit off from perfectly vertical the impact wont be that pronounced. Start with the 1.0mm drill bit then move to the 1.5mm. Drill into the rod about 6mm. Slowly tap the hole with your M2x0.4 bottom hand tap. I first used a tapered tap to start the threads then moved on to the bottom tap.
Step 4: Repeat Step 4 for the remaining bottom portion of the shift pin.
Step 5: Screw in the M2x10 set screw about half way down into the shift pin.
Step 6: Screw the slotted top portion of the shift pin onto the set screw.
Step 7: Fine tune the position of the slot by adjusting how much the set screw is screwed into the shift pin. For example if you find you need the slot to rotate more to the right, back out the set screw from the bottom portion of the shift pin then reattach the top portion. The slot should be angled slightly left.
Step 8: File down the bottom of the slot by at least 2mm. The total slot "height" should be 12mm.
Step 9: Apply some lithium grease to the slot and shift pin.
Step 10: Install the new shift knob. Make sure you push it all the way down until the bottom of the plastic lock ring inside the boot is at the second notch in the metal sleeve.
Step 11: At this point you should be able to easily press in the shift knob button and it should release smoothly.
Step 12: Remove the shift knob then either apply some Loctite to the set screw or use some sort of epoxy between the two shift pin pieces. I dont think this step is necessary because the shift knob pin will keep the shift pin from rotating free but its a good precautionary step. I ended up using some Gorilla glue between the pieces because I didnt have the right Loctite. Reinstall the shift knob and tighten the collar around the metal shaft.
Step 13: At this point you should have successfully completed this mod. Pat yourself on the back and go drive your car! Good luck!
If these steps make anyone queasy, I suggest purchasing 1/4" nylon 6/6 or abs rods (should cost much less than $1 for a 12" piece) and practicing the drilling and tapping. Hopefully this will give you the confidence. This really is a very straightforward project.
Here is a pic of the shift pin with the set screw in it.
Here is pic with the slotted portion screwed on (I had to actually make another slotted top portion because I ruined the original piece using the heat and twist method):
Here is a pic of knob installed:
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Originally Posted by Storm33
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