Join Date: Jun 2005
Location: Cape Town, South Africa
Re: Removing Actuator
Not sure if you solved the problem yet but if not try the following.
With the actuator off and the shaft exposed clamp a vice grips/pliers onto the shaft. Not too tight as you will scar the shaft and make fitting the actuator a bit problematic.
Now, can you push the shaft into the gearbox? try to wiggle it a little (left to right) to get it to go down. You need to push it in so that only about one 15mm of the shaft is exposed, now move the shaft left and right. (First and second gear are in that position and should be selected you'll hear the gears being engaged)
Move the shaft to the centre position and let it come all the way to the top again.
Then, push the shaft about midway down, when moving the shaft left and right, you should select 3rd and 4th gear.
Again, move it to the centre and let the shaft come all the way to the top.
Lastly push the shaft about 5mm down and move left, then back to the centre, and again 5mm down and to the right. These will be 5th gear and Reverse.
If you can verify this manually, then mechanically you do not have a selection problem and your issue is with the actuator.
If none of this is possible, you may have an issue with the gearbox.
Also note that without the actuator on, there will be play in the shaft because the shaft goes into the actuator. The actuator has a lip about 3mm wide which fits into the geabox. When everything is put together there won't be any play.
Please let me know if any of this makes sense.
I can help you further once you confirm all of the above.