Stripped serrated "threads" on gear shift peddle

[mendoAu]

I know that I could buy a new one for my 84 200es. But thought I'd toss this out there to see if anybody has had success in "fixing" this problem. Just to many miles, to many shifts and possibly a bit loose at times. The serrations on the trans shaft are in pretty good shape but without good serrations on the peddle slippage is almost positive to happen. And as often as I have to pop the side cover off of this puppy spot welding isn't an option, HA!

[El Camexican]

You might try drilling and tapping for a serrated set screw (or two) in the lever and then filing a small flat spot on the shaft when you are sure of it's position. Never had to do it, but anything is better than welding them on.

[jb2wheels]

Sometimes Tecate shifters are hard to find and they like to strip. I used parts from another shifter to fix it.
http://www.3wheelerworld.com/showthread.php/166770-My-Red-Tecate-Project?p=1320568#post1320568

I would have just bought another shifter if I could.

[atc007]

Very simple. Put your shifter in a vice. Run a hacksaw through the gap twice,or a cut off tool once. You now have enough gap for it to clamp down like new. This works on all but the smooth stripped ones. New bolt if yours is at all stripped of course. Never be lured into welding or a bolt and nut. All bad ideas.

[83ATC185]

I wonder if you could also fill the splines in the lever with a little bit of lead solder and tap it on to create new splines? Just a thought.

[Dirtcrasher]

Nah, leads to soft... And I believe Bill is saying, " - Cut through the existing gap and slightly into the opposing side, it will clamp down like a shark... :D

Someday I hope to make splines :lol:

[Gabriel]

The ID splines of the Honda gear shifters seem to be dead soft material. I don't KNOW if this was an intention design but it makes PERFECT sense to do so. In any mating pair of parts, one will wear more than the other. Better to have a the shifter fail and change it in 10 minutes than a shift shaft fail and tear half the motor down.


Dirtcrasher, you can cut the splines of a shifter on a Bridgeport if you're patient ....and desperate enough. Using a piece of HSS, grind a single point broach, put it in a collet and then flip the head into low range so it won't move. Use a rotary table to index and your Y axis to feed in slowly while reciprocating the quill. Basically, it's a precision 3 axis arbor press for broaching. Be sure to pass all the way through. Broaching a blind hole in this manner is a recipe for disaster. Found that out the hard way.
I've done this [not for a gear shifter] and it's doable IF you grind the tool right first. BUT.....it sucks donkey and I would hate to know I had to do it again.

[El Camexican]

Someday I hope to make splines :lol:

Maybe practice on this style ;)

254810

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[mendoAu]

Thanks guy's, first off...that's a very strange "tapered spline shaft". Gotta be British judging from the overkill thought but not good in reality thing. I already tried the "making the gap bigger" thing but this steel just won't flex together even with a bigger gap, larger grade 8 bolt with newly tapped threads. And yes...this puppy is dang near smooth on the inside. So far I'm leaning towards the "cut one off a more common shifter " and weld it onto the original one. At the moment I'm using one from an '81 110 but I gotta leave the pull starter and cover off for it to fit. And like mentioned...I'm lucky that the trans shaft splines are still in great shape.

[yaegerb]

I am all for getting creative and trying to fix stuff but sweet jeebus how much is your time worth to you. I bet this guy would take 10 bucks for this lever.

https://www.ebay.com/itm/1984-HONDA-BIG-RED-ATC-200ES-SHIFTER-LEVER/163291732195?hash=item2604f218e3:g:b6sAAOSwLrdbg2g N