Stiff gearshift problems.

[Bill Sutton]

Hi There All.

After being away for several weeks, and the poor old cappo being sat outside in all weathers, I took it out yesterday, apart from a flat battery all was well for about ten miles, then the gear shift seemed to stiffen up, quite suddenly, like it had dumped it's oil. It hasn't. Wear and tear would presumably be gradual in nature, this seemed to be fairly rapid degeneration, only in shifting, no problems with the gears themselves.
I did read former posts suggesting water ingress down the gear lever itself, not the box. So, how do I gain access? presumably by removing the centre console? I can find no reference in the manual, found the lever and explanatory diagrams, but not the centre console, which has the petrol cap release, window switches, rear screen mech etc. Don't want to proceed on a "trial and error" basis, as I seem to specialise in the errors mainly.
Is it listed in the manual? if so what page? if not, how should I proceed? Judging by "new" non genuine screws visible, I'm guessing this is not the first time access has been required, so probably a recurring issue.

Thanks for any advice.

Bill

[Ian Linden]

Hi Bill,

Removing the center console is not documented per se, but is not exactly a dark art. There are (I think) four screws, plus, if I remember correctly (it's years ago) you have to lift out the rubber bottom from the central locker to get at some screws in there as well. Clearing the rear window release is a bit of a fiddle, but it does come off.

Hopefully, application of Molybdenum Disulphide grease to the linkage will sort it out.

[Bill Sutton]

Thanks for that, i would've missed under tne mat and broken something for sure!!! Here's hoping it's an easy fix.

[Murray Betts]

It's not a problem I remember anyone reporting, not that it's of any help to you.

Let us know what you find.

I assume the clutch adjustment is OK? Should have about 20mm or so of free play in the pedal before you feel the resistance. The cable adjuster is down at the gearbox end where it fits into the release arm, more or less under the drivers legs. Hopefully it's been greased and isn't locked up solid.

[Ian Linden]

You may be able to access the gearshift mechanism without disengaging the console from the rear window control - I think it will lift up from the front.

[Ian Linden]

Also have a look at figs 72 and 28 in the EA11R Parts Catalog.

[Martin Williams]

I have occasionally had the gearshift going stiff too. I have assumed it has been stiffness where the gear linkage goes through bushes. It has freed off again after a while and is not causing any more problems. I even had one morning where it seemed to have frozen! Obviously driving on very wet roads! I think the only way of getting to the problem area is to take the gearbox out and partial dismantle. I do not think you can get near the area from above.

[Bill Sutton]

Hi all,

I managed to get the centre console out and the lever removed, and yes, the gearshift housing was swimming in water. With the aid of a syringe, I managed to remove about 100ml (10X 10ml syringe) of rusty water from it, slapped a load of grease into the ball and socket, and the cutouts on the lever itself. It now works beautifully once more. However, in walking from car to garage, the washer on the plastic flange parted company and fell into the long grass never to be seen again. Not the wavy thrust washer, the one that sits on the top of the flange, presumably as a mating surface for the thrust washer, to stop the plastic wearing. As life is too short, i reassembled without this, it works fine but will wear out the plastic in the fullness of time. Anyone got a spare, or know what to call it should I have to phone Suzuki (god forbid).

[Ian Linden]

Not sure which part you mean, but all parts are shown and named/numbered on Fig 28 of the Parts Catalog in the manuals section.

[Bill Sutton]

Yes, had a look at the diagram, it's listed as "shim" but from my brief recollection of it, it didn't have a cut out, that would explain why it fell off when I had it down as circular and therefore not "at risk" so to speak, silly me.

[Ian Linden]

You could always make one up - it's stated to be 0.6mm thick.

[Bill Sutton]

Gear shift working fine now. Just to say, the previous owner had reassembled the lever the wrong way round!! I wondered how the designers could have got it so wrong as there was no clearance between the gearshift and handbrake levers in first gear, so I tried it the other way, and what do you know? it was offset the wrong way!!! some people eh.

[Ian Linden]

Some one with very short arms?