Forge Short Shift Kit - Group Buy

[End User]

Hi All,

I'm organising a group buy for the Forge Short Shift Kit. (http://www.forgemotorsport.co.uk/content.asp?inc=product&cat=&product=FMVAG5QS)

http://www.vwwatercooled.com.au/forums/

Endorsed (http://www.vwwatercooled.org.au/f127/what-did-you-do-your-polo-today-11306-377.html#post649898) by VWThunder as one of the best bang for your buck mods to date!
We need at least 10 members interested to secure the amazing price of AUD$105.00 delivered to your door :banana:

Please reply below to register your interest. This group buy will close on Thursday, the 21st of April.

Provided they are in stock, they should be delivered to your door within 2 weeks of this date.

[IN]
End User
noone
Blitzen
kangfu
DeanB
bn1986
Evaded Motorsport
walkerchan
chuck
Smead
kaanage
bfeboi

[Tentative]

[vwthunder]

Getting on to the fitting, well it was easy for me as I dont have my battery etc in the way, if anyone has the 42DD solid bushes they will know.

Once you can access the part, all that needs to be done it to remove 2 clips and it should come off, actually it was a bit hard to get it off as it has been on for a while. The forge instructions say to rock it back and forth and it will come off, and it does.

I would reccomend doing the 42DD bushes at the same time as it is not as much work, as your half way there. PM Greg Roles if you want some

[noone]

I said I was done... But I'm in...

[Bflat]

I'm keen too. Will have to check out Troy's before I give a concrete 'yes' though.

[Blitzen]

I'm in... That's an awesome price!!

My Kiwi wifi and iPad holder can wait till next fortnights pay...

[kaanage]

I'm keen too. Will have to check out Troy's before I give a concrete 'yes' though.

ditto - hopefully this Saturday

[kangfu]

I said I was done... But I'm in...


Lol.

Count me in too.

[Spec83]

I am tentative at this stage... Will have a look on the weekend and weigh up the 'easyness to fit' vs reward case

[DeanB]

Count me in.

I thought I'd stopped tinkering - obviously not !

[bn1986]

definitely keen too :)

[Evaded Motorsport]

Yeah keen for this to.

[walkerchan]

I'd definitely be up for one

[noone]

Looks like we have the numbers.

When I had my SAI bypassed, there was plenty of room. If you remove the intake pipe and disconect the SAI hoses from the intake box and return air extension (near the diverter), you may have enough space to get in there.

[Chuck]

definately in if there is still room to get in!

[End User]

definately in if there is still room to get in!

I've added you to the list in the first post.

For everyone else, the numbers are not limited to 10, we only needed 10 to secure the discounted pricing.

[kaanage]

Maybe post this in the MkIV and onwards Golf forums since it was design for those (to get bigger numbers)?

[vwthunder]

As much as i like it, some people not as a friend tried it and he didnt like it lol, bit too clunky for him

[DeanB]

As much as i like it, some people not as a friend tried it and he didnt like it lol, bit too clunky for him

That clunky feel would be made worse though because of the 42DD bushes ? I thought they made it more clunky as well ?

[Smead]

I'm in too if its still possible

[vwthunder]

That clunky feel would be made worse though because of the 42DD bushes ? I thought they made it more clunky as well ?

Hmm I think most of the harshness comes from the short shift linkage, with the 42dd bushes it is a little notchy, but with the shortshift you really have to work hard on long drives, as it requires more force to get it into gear

I guess it comes down to, do people want their polos soft or raw :P

[Greg Roles]

When I first put in the 42DD bushes I couldn't believe how much tighter yet notchier it felt. Now that I'm used to it I want more.....

[Evaded Motorsport]

When I first put in the 42DD bushes I couldn't believe how much tighter yet notchier it felt. Now that I'm used to it I want more.....

Greg I got your PM ages ago, I was trying to work out what I was going to do with the gearbox then forgot to reply, (your post just reminded me). I'll get in touch with you once the forge group buy is a little closer to being delivered.

[End User]

Hey Guys,

I spoke to Greg from carformance and he has kindly offered anyone buying the short shift kit a discount of $10, and free postage (in Australia) on the 42dd bushings (http://www.carformance.com.au/audi-after-market-parts/shift-bushings.html). This brings the price down to as low as $39, inc postage, depending on your year model.

If you are keen to kill two birds with one stone please PM Greg Roles directly to take advantage of this fantastic sub-offer.

[noone]

Props to Greg, very nice guy and easy to deal with.

[Chuck]

Hey Guys,

I spoke to Greg from carformance and he has kindly offered anyone buying the short shift kit a discount of $10, and free postage (in Australia) on the 42dd bushings (http://www.carformance.com.au/audi-after-market-parts/shift-bushings.html). This brings the price down to as low as $39, inc postage, depending on your year model.

If you are keen to kill two birds with one stone please PM Greg Roles directly to take advantage of this fantastic sub-offer.

awesome, think im keen for both but have 2 questions

what do the bushings do? :)

if i email Greg will he be aware of what im talking about? ie, is he a forum member?

[noone]

Greg is a member, he posted 5 posts ago... As for info on these parts, use the search feature.... I use the Google search mostly, enter the Polo section html (Polo (9N & 9N3, 2002 - 2009) (http://www.vwwatercooled.org.au/f127)) then the word you want to search for (eg Verdict, 42, etc). As I've mentioned, there is a guide for this on the Forge Wesbite. 42DD or Verdict have one as well for their part.

There are 3 parts in total associated with the shift so far;

- 42 DD bushes
- Verdict bushes
- Forge Short shift

The short shift, is well, just that..

The other bushes are designed to replace rubber parts with metal / alloy to create a more direct hookup.

Are they for you? If you like to tinker, then an option. BE AWARE, the 42DD ones require you to butcher the links a little to make space for the new parts. Would have to buy new bits if you wanted to revert... Guide on their website.

[Blitzen]

I'm keen to get both... I'll tripe it with just the short shifter, then I'll add the the bushes.

[Greg Roles]

The "bushes" replace the sloppy rubber ends of the shift cables. This makes your gearstick a LOT more solid, and the H pattern much more defined. Feels like you have a very direct link to the gearbox, feels quite different at first, but now I can't remember anything different. Certainly no missed shifts once you set it up right. The short shift will make the actual movement between gears less, so the H will be "smaller". A short shift by itself will have less movement for the pattern, but the lever will still be able to move around the same when "in gear". Make a note to feel that in gear movement next time you drive, with 42DD bushes it pretty much disappears and makes even the stock throw a lot more solid and swift.

I have had problems in the past with aftermarket short shifters, as the 42DD bushes are machined to exact OEM ( standard ) sizes. On some short shifters the manufacturers make the shafts a bit bigger to engage the sloppy stock rubber bushes better, and as such the 42DD ones won't fit without modification of either the bush inner, or the short shift shaft. You guys need to check with Forge if the short shift shaft is OEM or upsized, as I've not encountered the Forge unit as yet. Pretty simple and worthwhile to get around all the same if it is the case, but makes it a bit more fiddly.

Here are the stock cable ends on a MKIV Golf / early MKV Polo, they just push out, new bush slots in. You earlier model guys get it easy!
http://www.vwwatercooled.com.au/forums/images/imported/2011/04/n669619369_1984278_2104007-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/mk5_6s_bsh04-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/mk5_6s_bsh05-1.jpg



Mid MkV Golf, later MKV Polo have a more complex bushing kit that rebuilds the now plastic stock shift linkage pivot as well, and it is a much more involved. So much so I have made a fitment video as it is a little tricky, but oh so worth it. You can see the new black metal pivot in the foreground of the final pic, very different to the stock plastic item in the later models.

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/mk5_6s_bsh13-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/mk5_6s_bsh14-1.jpg

Happy to return / swap / send you both sets if you are on the cusp of model years. I think bang for buck these bushes are an awesome mod, but as I don't have a short shifter personally, it will probably take a few of the more adventurous amongst you to try the bush as well and report to the group.

I'm not going to retire on the profit from bushes, so no hard feelings if you decide to pass!

[noone]

Wonder if they would do a batch for us with this in mind? I'm less worried about another $10 than I am about getting something I cant work with my own tools / hands.

[Blitzen]

Thanks for that man... I'm not sure what bush kit I will need, but my car is a August 07 build. I will endeavor to see what my linkages are like tonight... I may need to pull my air box out to confirm it.

[Greg Roles]

Wonder if they would do a batch for us with this in mind? I'm less worried about another $10 than I am about getting something I cant work with my own tools / hands.

Fraid 42DD don't do numbers less than 250 for a run. Have already asked for multiple Aus specific things....

I believe "end user" is already onto Forge?

[Greg Roles]

Thanks for that man... I'm not sure what bush kit I will need, but my car is a August 07 build. I will endeavor to see what my linkages are like tonight... I may need to pull my air box out to confirm it.

So far it's pretty much year for year, highly likely the 07 bushes are the go, and they are the easy ones!

[noone]

Yeah, was thinking Forge greg... Already have the 42DD ones in.

[Greg Roles]

Ahh yeah, so you do! Carry on....

[kaanage]

with the shortshift you really have to work hard on long drives, as it requires more force to get it into gear

I guess it comes down to, do people want their polos soft or raw :P
I really liked the feel of your shift on Sat but the heaviness would worry me as I shift a LOT in traffic - just as a note for others, vwthunder has his set to the very shortest throw so it may be less of an "issue" when adjusted towards the longer throw.
It would be GREAT for a track sprint race but problematic over an endurance race

And yes, I'm a soft old fart and like my Polo that way!:cookie:

But I'll get on board for the shifter group buy if it goes ahead.:P

[noone]

Sounds about right, if you look at the guide you can see a long bar used as a counter weight (I assume) attached to the removed piece.

[vwthunder]

After a long drive on Sat 550km down the Great Ocean Rd and back, it was quite hard work shifting, but i was quiet tired. I only really noticed it in spirited driving, when my arm started to get sore lol, but asaying that i am happy that i have it

[kangfu]

After a long drive on Sat 550km down the Great Ocean Rd and back, it was quite hard work shifting, but i was quiet tired. I only really noticed it in spirited driving, when my arm started to get sore lol, but asaying that i am happy that i have it

TOO raw eh? :facepalm:

[Tim]

After a long drive on Sat 550km down the Great Ocean Rd and back, it was quite hard work shifting, but i was quiet tired. I only really noticed it in spirited driving, when my arm started to get sore lol, but asaying that i am happy that i have it

Its ok your left arm just doesnt have the strength that your right arm has Troy.. It will do you good to get some balance between the two now :D

[vwthunder]

Haha, nice one tim, now we can all have both arms the same strength lol

[Greg Roles]

OK if you do want to take up the discount offer on bushes I have set up a coupon on my website to give you the discount and free post. Please PM me to get the code. Kangfu ol mate, get onto me, you were so keen to buy some you paid full price before I could set up the discount code,so I owe you a part refund!

Add the bushes you want to your cart, then go to the TOP right hand cart link, NOT the express right hand side "checkout" half way down the page.

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/home-1.jpg


On this first page you can enter the coupon code. The express checkout skips this screen. In the shipping screen you wll now have free post activated.


http://www.vwwatercooled.com.au/forums/images/imported/2011/04/discount-1.jpg

Those of you with later cars ( eg 08 plus ) and are worried about the install of the more complex "drill bit" bushing kit, PM me and I can send you my fitment video to see if it's something you feel you could do or not. The written instructions from 42DD are quite daunting at first glance. You can always just buy the bushes and leave out the pivot rebuild ( the hard part ), I can just get those bits from 42DD and do you a price. Would certainly be better than nothing! That said, the difference on my Golf with normal shift arms was night and day. Driving a stock car feels horrible now!

[Blitzen]

Cool as. So when do you need the money for the short shifter and bushes??

[Smead]

Yeah same same mate, Can you let me know when you need the money for the shifter & bushes?

[kangfu]

Kangfu ol mate, get onto me, you were so keen to buy some you paid full price before I could set up the discount code,so I owe you a part refund!

Don't worry about it Greg, you are doing a great service for the VW community so you deserve any extra $ you get. :)

[Greg Roles]

Nope, I've set it up as credit on future orders mate, a deal is a deal!!

Appreciate the kind words all the same, just wait till you see what else I have in the pipeline to bring in : )

[End User]

Cool as. So when do you need the money for the short shifter and bushes??


Yeah same same mate, Can you let me know when you need the money for the shifter & bushes?

Hey Blitzen/Smead,

PM Greg for the discount code, and buy the bushes through the carformance.com.au website directly.

For the Forge short shifter, I will PM everyone the account details to deposit into once the official date for the group buy closes on Friday.

[Spec83]

Had a look tonight when I was putting the stock airbox back in and looks a tad complicated... Think I will give the shift mechanism a miss but the end links look not too bad :)

[Bflat]

Guys, call me chicken-*****, but I'm going to bail on this one.
As much as it's a steal price-wise, and the excellent level of support by Greg, I'm pretty concerned about returning the car to stock (or as close to) when it comes time to move one.
At the end of the day, even if they are long(ish) throws, I'm just happy I get to decide when they move :D
Auto's can go to hell.

Very much looking forward to peoples reactions and fitting experience (someone do a thread!)

[vwthunder]

You want a write up, not much to say really, quite simple modification, one part comes off and the new one goes on, except for the 42DD bushes have to be drilled out a little.
I found a drill bit which was like .001mm bigger than the hole in the bush, sprayed a bit of WD40 and it took like 4 seconds to get the drill bit through, it fits like a glove now

[Spec83]

It's the fact that it looks like I need to remove the battery to get at the shift mechanisim... The bushes look not too bad to get to after you remove the airbox, I am just not sure I have the tools to get at all the little clips etc.

[Chuck]

im not attempting either with my desk jockey hands...will have my mechanic install both

[kaanage]

the 42DD bushes have to be drilled out a little.
I found a drill bit which was like .001mm bigger than the hole in the bush, sprayed a bit of WD40 and it took like 4 seconds to get the drill bit through
Could you take a poofteenth off the Forge shift pins on a lathe to get the correct clearance?

[vwthunder]

I think it is easier to take it off the bush, as it only takes a few seconds

[Greg Roles]

Either works, but have you got a firm response from Forge about the pin size vs stock?

Here's how fitment works for you guys:

MKIV 5/6speed MY02-05 (42-455-001) easy install, just push in bushes.
MKV 5 speed MY06-07 (42-455-011) easy install, just push in bushes.
MKV 5 speed MY08-09 (42-455-013) harder install with extra pivot rebuild ( which is still optional ) ( see pic )

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/mk5_6s_bsh11-1.jpg


MKV 6 speed MY06 (42-455-005) easy install.
MKV 6 speed MY07 (42-455-007) easy install.
MKV 6 speed MY08-09 (42-455-009) harder install with extra pivot rebuild ( can be optional )

So any of you with 08/09 models, you have the more complex kit with the drill bit, and whilst you also just push in metal bushes, you are best to rebuild the plastic pivot. That said, if you just want the bushes and forget the pivot step, I can cater for that too, and do a bush only 08/09 kit. I'm touching up the fitment video, and will post on this thread later today.

Fitting the "easy install" bushes, is well, very easy!

Here's the 42DD tech page, I'm still adding all the tech stuff to my site.
42 Draft Designs (http://www.42draftdesigns.com/tech/shifterbushings.html)

[Greg Roles]

Hold up on ordering bushes people, still trying to sort out exactly which one fits the side to side in the MY08/09. The picture above is the Golf MY08-09 6 speed kit, but is virtually the same as the MY08-09 5speed one with the rectangle bushes. Seems the MY08-09 Polo GTI has all round bushes. The info 42DD are giving from the States possibly suit our Aussie cars, and I have a few Polo people who ordered bushes in the last groupbuy that have now worked out what they were advised directly from 42DD hasn't fitted on one half. Stay tuned, I'll sort it!

Also I haven't sent anyone the video, as the Polo kit is a LOT less complex than the Golf kit I made a video of, you do still rebuild the pivot a little, but nothing like the Golf version. Man, I'm learning Polo at a great rate of knots!

[End User]

Hi Guys,

Just an update on the short shifter kit. I'm waiting for bank details from Rennenhaus. I will pass these onto those participating in the group buy as required. Once you have transferred the money, please PM me with your name and delivery address.

[Chuck]

Hi Guys,

Just an update on the short shifter kit. I'm waiting for bank details from Rennenhaus. I will pass these onto those participating in the group buy as required. Once you have transferred the money, please PM me with your name and delivery address.

So are we transfering coin to yourself End User or directly to Rennenhaus?

[End User]

So are we transfering coin to yourself End User or directly to Rennenhaus?

Money will go to Rennenhaus. Rennenhaus will place order.
I will collate delivery addresses and pass these onto Rennenhaus.

[Blitzen]

When are they going to require the money?

[Greg Roles]

OK have just been speaking with 42DD, and the bottom line is they thought the MK4 -001 kit suits up to MY07 ( correct for the HWY box ), and the 5S MY08-09 -013 kit was suitable for the later MKV Polo ( with the 02A box ). Feedback from Kangfu is that this doesn't fit on the plastic vertical shift mechanism that controls the side to side gearstick movement on the 08-09. I will be sending him ALL the round bushes I have to see if he can work out the ones that fit, as well as another 09 Polo customer who got a MK4 -001 kit direct from 42DD and wanted to order more from me. Between the two of these guys we should come up with a world first late model Polo solution! I will get in a special order for the groupbuy and 42DD are keen to assist getting it correct.

Anyone out there with an incorrect set from either myself ( from the initial buy in ) or from 42DD themselves direct, please get onto me once a solution is sorted and I will swap out the correct bushes for free.

Sorry for the delay everyone, seems we are pioneering down under yet again!

[Chuck]

OK have just been speaking with 42DD, and the bottom line is they thought the MK4 -001 kit suits up to MY07 ( correct for the HWY box ), and the 5S MY08-09 -013 kit was suitable for the later MKV Polo ( with the 02A box ). Feedback from Kangfu is that this doesn't fit on the plastic vertical shift mechanism that controls the side to side gearstick movement on the 08-09. I will be sending him ALL the round bushes I have to see if he can work out the ones that fit, as well as another 09 Polo customer who got a MK4 -001 kit direct from 42DD and wanted to order more from me. Between the two of these guys we should come up with a world first late model Polo solution! I will get in a special order for the groupbuy and 42DD are keen to assist getting it correct.

Anyone out there with an incorrect set from either myself ( from the initial buy in ) or from 42DD themselves direct, please get onto me once a solution is sorted and I will swap out the correct bushes for free.

Sorry for the delay everyone, seems we are pioneering down under yet again!

Thanks Greg....ill check my build details tonight and shoot you a PM with more info....we might be able to get the correct set out first time instead of me returning the wrong ones

[Smead]

Can you let me know to whom and how much I need to transfer?

[bfeboi]

Can You kind gentlemen add me to the list and PM details plz. Cant wait to try it out on the track =)

[insanekiwi]

I really want more reviews on the short shift before I decide to jump in. I do drive a lot in rush hour, and making the shift a lot more hard work is not my goal. I do like the idea of shorter shift though... I hear that there is a setting from short to short-short. What sort of extra effort are we talking here? My car currently with all washers replaced do slot in very nicely.

[Buller_Scott]

making the shift a lot more hard work is not my goal... I hear that there is a setting from short to short-short. What sort of extra effort are we talking here?

basically, you're going to have to start taking musashi protein powder until you're able to bench a 150kg 5 rep max at the gym...

haha just kidding. its friday, friday, gotta be silly on friday...

i'll be getting one sometime within the next couple of months, and it'll be going to the shortest throw available :D

[noone]

U be crazy Scotty, crazy...

I'll have a go, can always go back and flog it off later of it's not right...

Hm, think I should do some flogging, seem to have a lot of bits lying around atm...

[End User]

Hm, think I should do some flogging, seem to have a lot of bits lying around atm...

Are your coil overs in yet? What shocks were you running previously? I'm in the market to start upgrading my terrible stock shocks on HR springs combo.

[kaanage]

If you already have shorter/stiffer springs, you could just get some good dampers that match up to the higher spring rates.

So when will we be pm'd about payment etc?

[End User]

Hey Guys,

Apolgoies for the delay. Still no reply from Rennenhaus. I'm going to assume Ian is on holidays. Let's wait till Monday and see what happens.

[jasonc23]

http://www.youtube.com/watch?v=mmqFBMEVZUQ

[noone]

Looks good, thanks for the 2 finger demo.

Is that the shortest throw?

[jasonc23]

Looks good, thanks for the 2 finger demo.

Is that the shortest throw?

Yep shortest throw.

[End User]

Everyone listed in the first post should now have a PM.
If you have expressed interest in this group buy, but your name is not listed in the first post of this thread, or if your name is in the first post, but you haven't yet received a PM then let me know immediately.

[noone]

Thanks mate received.

For those on the fence, Julian has done a writeup (in a Skoda) at Autospeed, you can have a look here (http://autospeed.com.au/cms/A_112209/article.html?popularArticle)

[kangfu]

I want it noooooooooow. :p

[bfeboi]

Pm recieved. Email sent

[Chuck]

Pm recieved. Email sent

+1

thanks!

[Smead]

PM recieved and set email as well.

At the risk of sounding dumb, are the bushes neccasary?

[noone]

None of it is necessary, they are addressing different elements (shift length vs shift alignment play). Or so I think, only done the bushes, I prefer it.

[DeanB]

PM received - email sent - Thanks for organising this !!

Also, anyone firm on what 42DD bush kit we need for the late 08 (MY09 designation) 9N3 GTIs ? Want to get these so I can do it all at once, just don't want the wrong kit and be fiddling around with it all twice.

[Blitzen]

Have you guys started getting your emails back from Ian yet??

[kangfu]

I havent recieved an email yet.

[DeanB]

Nice timing .. I was just wondering the same .. no reply here either.

[Greg Roles]

On the bushing front, still awaiting the final verdict......

[Chuck]

Have you guys started getting your emails back from Ian yet??

negative on email

[Smead]

Have you guys started getting your emails back from Ian yet??

Nothin from Ian to me either

[End User]

Hey Guys,

Ian is still waiting on 3 ppl, as of this morning, to send through their details. Then he will generate all the invoices etc in one hit.

[kangfu]

Witch hunt!! :P

[noone]

guess i was 1 of them.

done.

[noone]

guess i was 1 of them.

done.

[DeanB]

Maybe you were 2 of them ;)

[End User]

Maybe you were 2 of them ;)

ROFL. Too funny!

[noone]

So we are still short?

[Evaded Motorsport]

I was one of the three and sent off the email either Friday or Thursday morning.

[walkerchan]

Same I was one of the three. Didn't get around to checking lol. But did it a few days ago. Thursday morning?

[End User]

Yep. All buyers have been accounted for. Order will be placed with Forge on Monday.

[bn1986]

i never got an email from rennhaus???

[Blitzen]

i never got an email from rennhaus???

He hasn't emailed anyone yet, he has just ordered the parts. When he has them in, he will email everyone with payment details.

[bn1986]

He hasn't emailed anyone yet, he has just ordered the parts. When he has them in, he will email everyone with payment details.

i would have figured he would have collected the money before placing the order etc?

but okies cool :)

any sorta ETA?

[leegil]

Hooray, contacted Ian and made it into the group buy. Now to contact Greg for the 42DD. Haven't done a group buy since my motorbike days. Thanks for organising. Now to stop any more luxury spending.

[bfeboi]

hows the 42dd solid shifter group buy gona work?

[End User]

hows the 42dd solid shifter group buy gona work?

PM Greg Roles directly. He will give you a code to get the group buy discount. Then, go to carformance.com.au, punch in the code and $ave.

[Greg Roles]

...but please wait till fitment is confirmed and announced. My main Polo test pilot had a minor accident and their car is in the panel shop till mid this week, so it's taking a little longer than expected....:(

[DeanB]

Thanks for the update Greg, I'll be ordering a set once I know which ones I need :)

[Chuck]

Rennenhaus email recieved and payment made

thanks for organising this...im excited!

[End User]

Hey Guys,

The order has been shipped from the UK. Rennenhaus expect it to arrive near the end of next week, or early the following week.
Then add on a day or two for Rennenhaus to on-ship it to your door! :banana:

[bfeboi]

emailed read. payment sent

[End User]

Great news guys. Our order arrived at Rennenhaus this afternoon. Ian will be shipping them to your nominated addresses tomorrow, so chances are, you should have them by this weekend!

[Greg Roles]

...and now I'm gonna be the bad guy!

My test pilot has only just got his smashed polo back from the smash repair and as such is going to trial fit this weekend. Should have gone with someone local!

I've asked End User to be another test pilot to speed up the process, and if he doesn't want to, I'll need another volunteer.

The problem is on the steel vertical shift mechanism, as the flat horizontal shifter you are replacing with the Forge Shortshift just takes one half of the MK4 bushing set. I'll need someone handy and prepared to get in there and work out what fits the remaining stock mechanism.

Apologies to hold up the new toy!!!!!

[DeanB]

Greg, any word on the correct bushes for a late '08 build GTI ? I remember it was being looked at by a few people.

[Greg Roles]

....post above mate, I still have no idea!!

[DeanB]

No probs Greg, I'm off on holidays to Europe anyway, so hopefully it will be all clearer which ones to get when I get back ... also will see what I can pick up over there :)

[noone]

Sweet, been looking forward to doing something under the bonnet. Think I'll put the shift fairly short, guess I can try a few settings but I cant see that happening many times.

[End User]

When I used to roll with the MX5 crew, we would organise what would eventually become known as a 'Dodgy Day'.
Basically, after every group buy, we would organise a day where people would get together at a deserted carpark, or someones house and meet other members, shoot the breeze, fire up the bbq, and most importantly help each other install whatever parts were associated with that group buy.
It was a way for the more mechanically inept to learn a thing or two from the more experienced members, and perhaps get access to tools that they would have otherwise had to purchase, or take to a mechanic to get fitted.
But perhaps the most valuable thing that came out of these 'Dodgy Days' was there was always a volunteer who would take photos and document the install, then create a DIY guide for whatever part we were installing. This became a great resource for any newbies or anyone who missed out on the group buy looking at installing the mod in the future.
I think the short shift mod would be perfect to kick off the inaugral Polo Dodgy Day. The install doesn't require a hoist, or any special tools, but is complicated enough to warrant some assistance for those less technically confident (like me).

I think there's only 3 or 4 guys in Sydney on this group buy, but I guess we can call it a mini meet and greet and extend the invitation to all Polo owners regardless of if they participated in the group buy or not.

You interstate guys can either drive down to Syd(!!) or organise your own Dodgy Day.

Thoughts?

[bfeboi]

i got a full set of tools but they are in my toolbox at work... and i dun think my boss will be too happy with multiple VW around

[Blitzen]

Unfortunately for me, I just had a shoulder reconstruction, so I'm having enough trouble buttering toast, let alone swinging spanners, so I won't be able to install this for about 2 months... That goes that same for driving my car too!!

[DeanB]

I'll be back in mid-July from Europe so I'll be looking at doing the install around that time.

[kaanage]

Mine's arrived!!
Thanks again, EndUser :)

Now who wants to be the 42DD guinea pig? (although vwthunder already has this combination so it's not too scary). I'd be willing if Greg was closer

[Greg Roles]

Tommy - End user is my extra guinea pig, he is getting all the bushes 42DD currently do overnight tonight for this weekend. My other non forum guniea pig should be attempting it on the weekend too - without a short shift, but the same problem remains.

The horizontal mech you are replacing with the Forge takes one half of the MK4 bush kit, and that's the same across all the pogo's.
The cars up to end 2006 with the HWY gearbox also take the other half, so a full MK4 kit suits them - too easy.

you later guys have to work out what bush is going to suit the vertical metal mechanism, and I know both the MK4 round bushes, and the MKV 08-09 Square bushes don't seem to suit. Hopefully the TT, or the other Jetta and 5 speed bushes will suit, there is a lot of common parts across the Vag range, and 42DD only make 5 different bushes total, and each car has a unique combination of these.

If we do need a custom part, 42DD will come to the party, but it will mean a delay on the second half of the bushing kit, as they will need to set up a custom run on the CNC machines. I'm just preying we can make something work from what is already available.

Take lots of pics Tommy!!!

Anyone in Brisbane is welcome over on the weekend, and I'll have a crack with them!

I'll post a pic of what I mean as soon as Photobucket is back up.

[bfeboi]

I got home and found a lovely little package with my name on it. Thank you for my SS kit. Now to get the bushes....

[Greg Roles]

PM replied. Below outlines the problem side in the 08-09's. This is off a USA Rabbit and I believe the Polo is a steel arm, but it's basically the vertical mech bush that is the problem....

http://www.vwwatercooled.com.au/forums/images/imported/2011/05/shiftbushtext-1.jpg

[Greg Roles]

The link to all the instructions 42DD have.....

42 Draft Designs (http://42draftdesigns.com/tech/shifterbushings.html)

Just so it makes sense to both the guinea pigs, and to you guys when you go to fit, the square end links take round bushes. Yep it gets confusing, but all the end links are either square or rectangular. The later model rectangular ones take a rectangular bush. There are no square bushes. Please see the first MK4 fitment on the above link, and the second graphic showing square links and round bushes. My TDI has one square bush, which took round bushes, and I can confirm they are a perfect fit!

[Smead]

Just fitted the forge shift kit OMG the shifting is AWSOME real tight and crisp

[bn1986]

fitted mine last night too..

getting the old bracket off the splined shaft was a b!tch but the shift is significantly improved :)

For everyones info u really need to take out the battery airbox and battery floor thing to access the shifter mechanism

[insanekiwi]

It's good to get more feedback - I really do want to know how much more force is needed to shift, as I drive my car in daily city commuting traffic for 1.5 hours / day. I want a nice crisp shift - but not at cost of extra tiredness.

More feedbacks please!

[bfeboi]

fitted mine last night as well. i needed a cam puller to remove the old shifter off the spline..

I feels tight and mechanical. less sloppy. it did not shorten the travel of the lever much but you can feel the gates of the gearbox when you engage gears, which is nice

[kaanage]

Fitted mine this afternoon. Even though my car is quite low mileage, the original shifter was frozen to the splined shaft too so I used a heat gun to expand the shifter enough to be able to rock it off. I used anti-seize rather than the grease supplied by Forge when I put the new shifter on.

My impressions are the same as bfeboi. The Forge shift saves a bit of weight since the original one has the big handle - does anyone know if this is for testing or emergency shifting?

I had always thought that the Polo had a reasonably short throw and the original shifter is equivalent to the Forge shifter set to about the mid point.

[pog]

Looks like mine was delivered to an old address Ian had on file. Awesome...

Probably best to go visit the place and ask. If anything it may get redirected to you or to the sender.

[Blitzen]

Looks like mine was delivered to an old address Ian had on file. Awesome...

Same here... Whats more, it was signed for by some random at my old address!! it's a bit hard to get it when it was delivered to Darwin, and I live in Canberra now...

Ian has been great though, and I have another short shifter on the way...

[noone]

Probably best to go visit the place and ask. If anything it may get redirected to you or to the sender.

Hm, how about I let Ian sort it. I don't know who lives there, they don't have a forwarding address. It's not the end of the world, but poor admin.

[End User]

Short shifter and 42DD Bushes installed!

Trickiest parts were:
1. Getting the battery cage off. Who ever designed this thing is pure evil.
2. Getting the original shifter mechanism off it's splines. This alone took 45 minutes, and destroyed my lower back.
3. Enlarging one of the holes on one of the 42DD bushes. Would have taken seconds if I had the right tools. The other 3 fit perfectly
4. Putting the battery cage back on.

Initial impressions:
Shifter was set to the shortest throw. The movement is much more precise and confident. Throw is noticably shorter. More effort is required to get into gear, but no where near an amount that will make your arm tired in traffic. And I'm a 60kg weakling.
My only gripe is that there is sometimes some notchiness into 2nd, 3rd, 4th and 5th. Hopefully it gets a bit smoother when things a bed in a little more.
Would have liked to try the short shifter without the bushes first, to gauge what difference each component makes, but two birds with one stone was too tempting.

Greg, I've got pics at home with which bush was used for the vertical link. I will email these to you tonight.

Anyone in Syd that hasn't installed theirs and would like some assistance, let me know.

[Greg Roles]

That's excellent news!!! I am uploading my bush install video to you tube right now, bit late for you Tommy, but may help everyone else.

Sounds like you need to slightly adjust the vertical mech cable length, and I'll have a video on doing that up in the next day or so. Basically making the cable end longer, moves the gearstick away from you, and making it shorter moves the stick to the left. I found just one notch on the cable end shaft made all the difference with notchiness. It's like the rubber OEM bushes have enough slop to allow the gears to "deflect" into place if the alignment isn't quite right, whereas having them tight you need to fine tune the H pattern alignment. BEFORE anyone tries that, mark the steel shaft with a nikko pen so you know where you started from, as just one "tooth" makes a big difference, and the stock setting is always perfect / close to!

Once I find out which bushes you Polo guys need, I'll most likely need to get a special order in, as it sounds like the 2008-2009 Polo kit will be a frankenstein mix of a few bushes from 42DD, and I only have about 4 kits of each model in stock at any point in time. Once Tommy lets me know the hole enlargement, I might be able to get a specific drill etc to prefab them before sending.

Anyone with a 2007 or earlier with the HWY gearbox can just run the MK4 kit, you have it easy, and I have more of them landing next week.

[Greg Roles]

Carformance Australia | Facebook (http://www.facebook.com/pages/Brisbane-Queensland-Australia/Carformance-Australia/153295634694999)

My new facebook page with the shift bush install video. Please like it!

[kaanage]

2. Getting the original shifter mechanism off it's splines. This alone took 45 minutes, and destroyed my lower back.

Anyone still to install their Forge shifter should get hold of either a cam puller or a heat gun to make this stage a LOT easier.

[Greg Roles]

Here's the two steps I think you have left to do Tommy, the rebuild of the cable end shaft, and the pivot itself, but I understand if you'd prefer not to go cutting things!


http://youtu.be/JHw3eRVASOE


Here's my attempt at explaining how to tweak the cable ends for notchy gears, especially if you do unhook the cable ends.


http://youtu.be/MYrh5989jMU

[noone]

Short Shifter went in today.

Do we need another review? I like it, its notchy, but short. IMO if you find getting the shift into the gates difficult, you may have one of the arms set to the wrong length. The gates make the shift pause, but you can't smash it in anyway, I don't find the shift heavier.

I was able to get the arms off without adjusting their length, I was able to get the old shifter out and new one in without removing the airbox or battery, just removing the intake section and disconnecting the SAI-airbox hose. Still took me most of an hour, but I'm pretty slow and like to admire the engineering and try to absorb some knowledge whilst I have new areas uncovered.

This mod is not for those who want the car soft and OEM, but for the tinkerers who think anything with a GTI badge should be raw.

[Blitzen]

Still waiting for mine to rock up...

[Smead]

Dont worry, You know it shifts sweet

[kaanage]

We don't all drive GTi's...........

[Buller_Scott]

We don't all drive GTi's...........

shhhhh! TDI's are SLOW - especially up over reefton spur (or old road, for sydney siders)...

i dont mind the mindset, though... it's always nice to reminisce over how brutally we both cornholed scott (swift gti driver) on the ocean road after he suggested that we trail at the back of the pack because our diesels "are going to be holding everyone up"....

[kaanage]

You don't have to be a fast driver to appreciate a nice shift. I particularly like the short throw for down shifts where I can just flick it though with my fingers.

[noone]

When I jumped into the car today, the shift felt a little heavier. I guess the gearbox oil was warm yesterday. Not a problem but different. I find getting out of 5th and reverse can require a little more effort, but otherwise it's short enough that I feel like I wan just flick the fingers or wrist.

[noone]

We don't all drive GTi's...........

Sorry, change that to anyone who thinks the Polo should be Raw...

No offense, just a high portion of GTI'ers.

[Greg Roles]

OK people, I am going to add a specific 08-09 Polo kit to the Carformance product line overnight, and this is what you need to order if you have an 08-09 model with the 02A gearbox. I will be ordering a batch of these in the next day or so from 42DD with the specific mix of bushings. This is the more involved kit that includes the pivot rebuild, but it's not essential you complete this step. In fact Tommy ( End User ) is happily running just the new hybrid bushes, and hasn't rebuilt either the link shaft ( which I would actually recommend ) or the pivot ( which would be best but is optional ). Before anyone starts cutting though, I would really like one person who knows what they are doing to do a test fit, I'm 99% sure the mechanism, thicknesses etc are idential, but it would be smart to check BEFORE modifying the stock shifter. Regardless this kit will come with all fittings, and with the discount comes to $45 with free post.

I'd prefer that someone in Brisbane comes over and we do a complete fitment, but so too most of you Polo guys seem to know what you are doing!

Please see my pivot rebuild video for info on that fitment. You will also need to view the bush fitting video.

http://www.youtube.com/user/CarformanceAU?feature=mhee

Everyone else with a MY 2007 or less, and with the HWY gearbox, can just order the MK4 bushing kit, more of which are leaving the USA today with a 4-5 day delivery to me. Your fitment is dead simple, and all you need to do is look at my first shift bushing install video. This kit comes out to $39 with free post.

http://www.carformance.com.au/categories/engine-transmission/shiftbushings/vw-shifter-bushing-set-mk4-5-6s-my02-05.html

Those who have already ordered / returned bushes etc will automatically get their items as stock arrives. Would be helpful to me if everyone could post a reply as to what they need, where they are at, what they have returned, just to make sure I don't miss anyone!!

You may have to do some minor inner diameter modifications to get the bushes onto the Forge links, and Tommy mentioned he needed to adjust one bush, perhaps I can ask him to put up his PM to me in a bit of an install post??

[noone]

Thanks Greg, great service.

[Greg Roles]

Seems the Polo's only differ on the vertical mechansim, all models in MKV run the MK4 bushings on the flat mechanism you are replacing with the Forge short shift. You will need to modify these B6FB52 bushes slightly to get them to fit the Forge shafts according to Tommy. The shafts must be slightly bigger than OEM, so will need a slight enlargening of the hole for one of the shafts apparently.

The earlier model up to mid 2007 runs the HWY box and uses the rest of the MK4 kit just fine. The later MY08-09 runs an O2A gearbox, and uses the vertical bushings, pivot and shaft rebuild out of the 08-09 6 speed Golf kit. I've used up my stock on hand fixing up the first three Polo guys on here I dealt with, the rest will be ordered in and take about a week. I have extra bushes coming back from my test pilots, so may be able to help a few more of you out before the main delivery arrives.

To check your gearbox version...

Grab your owners manual, and go to the service section here:

http://www.vwwatercooled.com.au/forums/images/imported/2011/06/IMAG02452-1.jpg



The next page is your car's detail sticker, and your gearbox is listed here ( red arrow ):

http://www.vwwatercooled.com.au/forums/images/imported/2011/06/IMAG02461a-1.jpg




HWY is the MK4 bushing kit. O2A is the later pivot rebuild hybrid kit.

[Greg Roles]

OK.

I have final details for you Polo guys, you don't need to rebuild the actual pivot in the 5 speed. Got this reply from 42DD overnight:
************************************************** ************
The 6 speed kits need the pivot rebuild as they are not designed as well as
the pivot on the 5 speed, the 5 speed vertical arm pivot is are much stronger
and feels far more sturdy when shifting than the 6 speed does out of the
factory. Putting the pivot rebuild on the 5 speed kit would not make any
difference in feel, and it's not required.
************************************************** ************

You will only need to drill and put a bolt through the shaft where the cable actually attaches to the vertical arm, and I will edit up my pivot video today to make a Polo / 5 speed specific version. I will put up the kit you need on my site today, and order a quantity in. In the end you 08-09 guys need the 08-09 5 speed kit, with the vertical bushes out of the 08-09 Golf kit.

It's taken a while, and I'm sorry I've gone around in circles to get here, but it's good news, as cutting your pivot arm is a pretty major mod, and you don't need to bother!

[Greg Roles]

And your very own Polo specific pivot arm install video. Thanks to all who helped out on this project, we just finished a world first for 42DD.

YouTube - ‪42 Draft Design 5 speed pivot install‬‏ (http://youtu.be/ECsApKDHzbw)

[Greg Roles]

And finally the link to your very own POLO MY08-09 product, with thanks to those on here who assisted the creation of this product!

I have one in stock now, made up from my bits on hand, the rest will be in early next week. PM me for group buy discount code if you still need to get it.

VW Shifter Bushing Set - Mk5 5 speed MY08-09 Polo (http://www.carformance.com.au/categories/engine-transmission/shiftbushings/vw-shifter-bushing-set-mk5-5-speed-my08-09-352.html)

[kaanage]

Just a slight correction - the 9N3 is still a MkIV Polo and the 6R is the MkV (sounds funny but that is VW's fault)
The kit looks cool but I have to stop modding my economical town runabout

[Catfish]

The next page is your car's detail sticker, and your gearbox is listed here (red arrow ): HWY is the MK4 bushing kit. O2A is the later pivot rebuild hybrid kit.

Doesn't appear to in my manual. At the red arrow it says JDB, not HWY or O2A, and it's an 07 Polo Gti. Can you interpret this?

Thanks.

[Greg Roles]

Poop, guess the Polo manual is different to the Golf!

Help Polo guru's!!!

[worx]

too late to get one?

[Blitzen]

too late to get one?

I think so man... Everyone has got theirs and installed them... Well everyone but me... Mine is sitting at Mascot...

[End User]

too late to get one?

You can still get a discount on the 42dd bushings. PM Greg Roles for the discount code.

[Greg Roles]

Discount was for those in the group buy who also bought a Forge short shift, afraid I can't sell them that cheaply forever!

Afraid there's so little in bushes that this offer was more a factfinding mission and a bit of love for the forum.

[worx]

ah well, worth a shot.

[Greg Roles]

Also afraid R fitment hasn't been worked out as yet....

[kaanage]

Here's my attempt at explaining how to tweak the cable ends for notchy gears, especially if you do unhook the cable ends.


http://youtu.be/MYrh5989jMU
This is awesome. Mine was slightly notchy after installing the Forge short shifter but one click inwards later and the shift is beautifully smooth again :)


Doesn't appear to in my manual. At the red arrow it says JDB, not HWY or O2A, and it's an 07 Polo Gti. Can you interpret this?
Thanks.

On my late '08 TDi, it says JXY there

[noone]

did you notice a problem at one end or the other (eg R / 5)? The feel of mine wilth all the bits is notchy, but not in a way I think needs to be changed... I don't have any gears that are hard to get into or more problematic

[kaanage]

I THOUGHT it was just generally notchy for all gears after instaling the short shifter. Then after looking at Greg's video, I felt the shift more carefully (with the car off and clutch depressed) and noticed that 5th was always a notchy while 1st was smooth if I didn't push the lever all the way to the left (just slightly off). One click shorter later and the notchiness is totally gone.

[Greg Roles]

This is awesome. Mine was slightly notchy after installing the Forge short shifter but one click inwards later and the shift is beautifully smooth again :)



On my late '08 TDi, it says JXY there

Glad my explanation worked, I'm still not happy with that video, but as you found one click makes all the difference!

I'll have to investigate Polo gearboxes further, was just told by a member that the later cars had the "02A" gearbox. Would LOVE one of you guys to set me straight there!

[lush4]

Someone Pm me if there is another group buy. Id get one of these in a second. I havnt been on here in a couple months.


MArk

[Blitzen]

Someone Pm me if there is another group buy. Id get one of these in a second. I havnt been on here in a couple months.
MArk

Why not try and start your own group buy? I'm sure there is a few more people that would like one.

[Greg Roles]

Polo specific bushing kits now in stock. Available at the group buy price to those on the first list. I have 10 sets, first in first served.

Thanks for making this new kit happen people, couldn't have done it without you!!


http://www.vwwatercooled.com.au/forums/images/imported/2011/06/IMAG0293-1.jpg

[Greg Roles]

half gone, 5 sets left.....

[Chuck]

Thanks for making this new kit happen people, couldn't have done it without you!!




thanks to you Greg for doing it...and your awesome service/follow up!

When are you going to stock rear sway bars? :)

[worx]

bought the diesel geek one, feels pretty good!

[bfeboi]

my solid bushes came in the post last week. now to find time to fit them. Thank you Greg for all you effort

[Greg Roles]

Mate, it was a win-win. Now there is a late model Polo shift bushing kit available ( first in the world for 42DD! ), and you guys helped me work it out. Also forced me to make some fitment videos, and to learn the editing software.

I now keep both earlly and late model sets for the Polo in stock.

[Chuck]

Short Shift and Bushings being installed today...will report back with my findings :)

[insanekiwi]

Got mine fitted - today and will report later this week.

[silver32]

Hi guys.

Just got the APR remap done today, goes much harder now. In the market to pick up the Forge short shift kit and 42DD bushes. Anyone else starting a group buy? Or what are the individual prices and who can I get them from?

[Chuck]

Greg @ Carformance

Carformance Australia - Automobiles and Parts - Brisbane, Australia | Facebook (http://www.facebook.com/CarformanceAU)

[Greg Roles]

Thanks Chuck ol' mate, but that's the facebook page : )

Here's the 08+ polo kit, I have stock, and only place in the world to do so thanks to the lads here.

Afraid the special price is over, as those kits went out at pretty much cost as a favour to my favourite forum.

VW Shifter Bushing Set - Mk5 5 speed MY08-09 GTI Polo Club Match (http://www.carformance.com.au/categories/engine-transmission/shiftbushings/vw-shifter-bushing-set-mk5-5-speed-my08-09-352.html)

Ian at Rennenhaus can sort you on the Forge Short shift
Home - Rennenhaus, aftermarket and performance parts for your VW, Audi, Mini, BMW, Honda, Lotus, Porsche (http://www.rennenhaus.com.au/)

[Chuck]

lol..sorry mate, only link i could find quickly....trusty facebook :)

[Greg Roles]

The best news of the day is that in the Golfs, the late model MKV shift kits suit the MK6, so I would assume this late model Polo kit *might* suit the MK6 Polo too!!

[leegil]

Has anyone in that ACT done the short shift and 42DD install yet?

I was going to attempt it but I don't want to get into a position when I have taken the car apart and then work out I have messed it up! If I was going to attempt it, I would naturally like to have somebody with experience by my side. I don't know if I have all the tools but sure have some (enough to strip a bicycle down).

Once I have done it then I am more than happy to help others likewise.

In return, I have the SRSII Console that I can DNA Tune your car for you (you just need to buy the DNA Tune, or I can get that very cheaply for you). Since I have the console already it is pretty simple to use the computer to extract and then upload the tune to your ECU.

Happy to assist and be assisted likewise in this community. PM me if you can be of assistance.

[kaanage]

Are you DNA Tuning agent?

If so, that's great that their netwok has expanded beyond Melbourne :)

If not, then I doubt you can use your SRS-II to flash anyone elses car as the customer version of this (the Alientech PowerGate S) is locked to a single car :(

[leegil]

Hi kaanage, I am not a DNA Tuning agent. I am just a basic consumer. It was cheaper for me to buy the SRS-II and the tune and do it myself. Very simple. The DNA tune can be purchased very cheaply. If anyone is in Canberra then happy to lend a hand.

Basically you need the SRS-II to read the OEM tune from your car. You then send the OEM tune to an agent (email with attachment). I went through a UK seller. A couple of days (maybe 3 days) a new attachment is emailed back to me. I then just load it up back into the car. I think it took me 30mins to read the original file and 30 mins to upload it back into the car. Obviously a lot of checking and double checking to make sure of no mistakes.

I keep a record of the original and the modified files just in case I need to go back to the original profile. Each modified file is unique for each car I believe (cannot use modified files for different cars -unique for each car and will need to purchase a separate tune for yourself). The SRS-II is just a file medium that you can move files. I store files on my hard drive and on the SRS-II and can interchange them as I like.

[kaanage]

Sorry leegil, that happens not to be the case - you can ask the UK seller or the local distributor, John, if you like. The SRS-II is a rebadged Alientech PowerGate S, just like my Viezu V-Switch, and it gets locked to the car when you do the original ECU download.

John or DNA Tuning in the UK can reset it but they would only do it if you are on-selling the unit. Once this has been done and another car downloaded, you would not be able to use the SRS-II to reflash your car.

See Alientech - Powergate II (http://www.alientech-to.it/index.php?option=com_content&view=article&id=53&Itemid=121&lang=en)

[leegil]

Thanks for clarifying. I thought it could but I am obviously mistaken. Never tried (as I only have 1 tune). Just thought it could be copied through like a USB key. I do know that I can have more than one tune to store on it but was not sure that it was locked to my car.

[kaanage]

No prob - I just wouldn't want you to make a promise to someone that you couldn't fulfill.
As for ACT, short shifting Polos, check with Blitzen or Smead - I believe they are also Capitalist Territorians and have the Forge short shifter.

[leegil]

Yeah, Blitzen is helping me out on Wednesday. Once I learn how to do it, and if I have the correct tools in my arsenal, then more than happy to help others out as well.

[kaanage]

I would still advise you to heat the original shifter up with a heat gun until it is uncomfotable to touch to loosen it off from the splines (then use a garden glove to pull it off). The battery cage is trickiest part but Blitzen will show you the trick in getting it off.

[Blitzen]

I just took the air filter box out... This gives heaps of swinging room.

[noone]

You can do it without moving either, disconnecting the 2 SAI hoses gives enough access (visibility is poor tho).

[leegil]

This is why I sought assistance...sounds like three different approaches. Simplicity is the key for me :-) I cannot even recognise the bits you are talking about. Thank heavens for a good community.

[Smead]

I just took the air filter box out... This gives heaps of swinging room.

Yeah Airbox is the way to do it. Also removed my PD 160 intake for a little extra room :)

[leegil]

Here's the update:

42DD was installed with Blitzen's help. First attempt went very bad as we did not mark the rod and this led to the H-pattern moving towards the bottom right (barely got into 5th gear). Once I worked out what was the cause and how to rectify it, we took another go a few days later with full success. Moral of the story...mark the rod before you remove the plastic jaws to insert the bushings. Note that markings on the rod are not threads, but circular grooves as markers and grip for the jaws. Special thanks to Blitzen and also Greg Roles for being 'on call' for the second rectification if required (was not required). If you do stuff up the rod length, it is easier to have 2 persons working on it (one adjusting and other moving the lever in the car to tell you if there is improvement -saves in/out of the car).

The short shifter was an absolute pain. Blitzen and myself could not remove it off the car spline. We had no leverage without removing the battery box (which we did not do). Ultimately I took it to Canberra VW Centre (CVWC) to install when they were doing the minor service and replacing the radiator. Damn radiator cores leaking by 70K km is ridiculous (my '95 Hyundai Excel went 160K km without issue). Back to the story, they had the leverage on either side of the shifter to apply force and 'wiggle' it off. Good work by Dean at CVWC.

The feel:
-42DD by itself was very direct and removed a lot of the 'rubber bounce' of OEM shifter. Shifting effort was just the same (no additional effort).
-Short shifter makes it a little more effort but also 'notchier'. The shortest setting is to my satsfaction, although I would have preferred to go even shorter if possible :-).

It all feels good now.

[Greg Roles]

I think Blitzen was the problem just quietly Leegil...:cookie:

[kaanage]

The short shifter was an absolute pain. Blitzen and myself could not remove it off the car spline. We had no leverage without removing the battery box (which we did not do). Ultimately I took it to Canberra VW Centre (CVWC) to install when they were doing the minor service and replacing the radiator. Damn radiator cores leaking by 70K km is ridiculous (my '95 Hyundai Excel went 160K km without issue). Back to the story, they had the leverage on either side of the shifter to apply force and 'wiggle' it off.
Did you try heating it like I suggested??

[Blitzen]

I think Blitzen was the problem just quietly Leegil...:cookie:

Hahaha... Thanks for that vote of confidence Greg!! Seriously though, once we worked out that the bush holders weren't screw ins, it took us less than 5min to adjust to the right position... As I had never pulled the bush holder/cable end off the shifting cables, I didn't realize it was going to be a as much of a problem as it turned out to be... That, and I have passion fingers!!

[Blitzen]

Did you try heating it like I suggested??

I didn't have the equipment to be able to do that... Also, I didn't want to burn his car, or my apartment block to the ground either!!

The stock shifter would move about 1mm up on the splines, and just stop. I tried DWF, WD-40, leverage, mechanical persuasion, reasoning with it, and good old swearing at it, but it just wouldn't move any further than that 1mm up on the splines shaft, and we tried for a good 2hrs, which really pissed me off, as my short shifter took literally 20min to fit... It just pulled straight off!!

I'm glad he is happy with the result though, as I'm sure he was going to be... And I thank him for putting up with my rather colorful language too!! I'm glad I could help out, and I'm sorry that I couldn't get the short shifter fitted on the first try.

[kaanage]

A heat gun won't burn a car if aimed at a metal part and stresses the components much less than levering or even a puller.

I removed a wheel bearing from one of my GP bike's wheels without using a heat gun once - it was brutal and then I remembered the heat gun immediately afterwards when I went about inserting the replacement bearing.

I'd forgotten it again when I went to remove my stock shifter until going through my own bout of levering, pulling, WD-40, Penetrene, swearing with not a trace of movement... That's why I recommended it here as the shifter then came straight off after a couple of minutes of thorough heating.

I then dug out some anti-seize to coat the splines before installing the short-shifter rather than use the red grease supplied by Forge.

[Blitzen]

Yeah, I know what you mean about the heat gun, I just don't have one, or have access to one right now. It's on the list to tools to buy, moreso now that I don't have a tool store at work where I can just borrow tools that I don't have at home... Right now though, my money is being directed into my trip to the USA, where I can buy and bring home almost anything I want (I wish I could ring back firearms!!), at a half to two thirds to what we pay over here...

[leegil]

CVWC (Dean) said it was really easy to remove, with a cheeky smile :facepalm:. He was able to wiggle it from both sides as he had access and leverage. I suspected that he would have removed a lot of stuff as he had to replace the radiator. The battery box got in the way. CVWC did not use a heat gun. He said it took him around 5mins just to remove the shifter itself from the spline.

Blitzen is correct that once we worked out the shifter rod did not have 'threads', it took us hardly any time to fix up the shifting. Very easy indeed (once you know).

What was also good was somehow CVWC also fixed the left headlight beam elevation without doing anything at all (the LHS was not dropping its beam down). Now it is.

Thanks heaps to all for their advice and help.

[kaanage]

Yeah, I know what you mean about the heat gun, I just don't have one, or have access to one right now. It's on the list to tools to buy, moreso now that I don't have a tool store at work where I can just borrow tools that I don't have at home...
Yeah, sometimes I forget that not everyone has a stupidly large array of tools (in my case due to the years of motorcycle racing as well as car maintenance). People are amazed at the amount of tools I bring to a track day - of course, they all wander over when they break something or something loosens up or needs changing...:rolleyes:


CVWC (Dean) said it was really easy to remove, with a cheeky smile :facepalm:. He was able to wiggle it from both sides as he had access and leverage. I suspected that he would have removed a lot of stuff as he had to replace the radiator. The battery box got in the way. CVWC did not use a heat gun. He said it took him around 5mins just to remove the shifter itself from the spline.


When I removed the battery housing, I had pretty good access/leverage to the shifter and it still wouldn't budge - it was almost like it was corroded on. Maybe Blitzen loosened yours up a bit with his aborted efforts.

One day, I'll get around to installing my 42DD bushings too (currently living in my glovebox) and will have your experience firmly in mind.

[Blitzen]

The DWF definitely helped, but even with the aid of a long drift punch or a 16in flat tip screw driver, I just couldn't get the leverage to shift it more than a millimeter. Before I sprayed some DWF in there, it was on solid. Dean at CVWC is a strong, strapping lad though, so he wouldn't have a problem getting it off though!!