Just rebuilt toploader pops out of gear

steve meltzer · #1 (**permalink**) 09-29-2016, 04:54 PM

Finally got the toploader back in my Kirkham. Went with the Kirkham mechanical t/o, but the car occasionally pops out of third gear, only. Gotta be in the rebuilt gearbox, right? Any chance that I didn't get the shifter arms adjusted correctly? arggghh. thanx steve meltzer, KMP #174

Grubby · #2 (**permalink**) 09-29-2016, 05:19 PM

I would double check shifter/linkage adjustment and remove the shift boot. It is possible a binding shift boot could push it out of gear.

They pop out of gear due to wear or damage on the gear. It is quite visible if you know what you are looking at. I suspect, if you did a good rebuild the problem is not in the box.

John

DanEC · #3 (**permalink**) 09-29-2016, 06:04 PM

If it's 3rd gear there is a possibility it's being caused by the rubber shift boot. Most of the ones sold for Cobra type cars are too thick and stiff. Mine was popping out of 3rd every once in awhile. I could put the shifter in 3rd and release it and see the boot pull it rearward.

I bought a new boot sold by Sunbeam Specialties which looks just like the Cobra boot but is thinner and more flexible. I installed it about 2 years ago and haven't experienced a 3rd gear pop-out since.

If you decide to try one the easiest thing to do is just call them up and order over the phone. They will know what you're looking for as I think they sell quite a few of them to Cobra guys.

Sunbeam Specialties - Number 1 Source for Rootes Sunbeam Alpine-Tiger Parts. We carry the most extensive range of mechanical, hydraulic, upholstery and restoration parts available.

I should add it's easy to check if this is the problem by just removing the screws from the trim ring and boot and leave it loose and see if it pops out of 3rd.

steve meltzer · #4 (**permalink**) 09-29-2016, 06:23 PM

I recall your post from my earlier troubles, and my boot is the one from Sunbeam Specialties. Let loosen the trim ring and check it. thanx. steve

DanEC · #5 (**permalink**) 09-30-2016, 03:03 PM

OK - if you have the Sunbeam Tiger boot then a couple other areas you might check are to make sure that when you accelerate in 3rd gear, the shifter isn't making contact with the edge of the tunnel cutout as the engine torques over. If you have through-bolted your driver side engine mount to limit torque movement, then this can probably be discounted.

What shifter do you have - a Hurst? The Hurst shifter has stops (bolts front and rear) to limit shifter movement to avoid overstressing the shift forks and internal parts on hard shifts. If you haven't already - it would be a good idea to check the front stop that limits shifter throw on 3rd gear. If it is too tight it might be limiting full 3rd gear engagement.

steve meltzer · #6 (**permalink**) 09-30-2016, 03:09 PM

thanx. i'm gonna take the car to the guy who built the gearbox in the AM, and i'll let you know. s

steve meltzer · #7 (**permalink**) 10-08-2016, 06:56 PM

The day before (Thrs) I was scheduled to take the car to the guy to rebuild the shifter, I took all of the screws that retain the boot ring to the tunnel, completely out, not just loosened a few turns. And, viola (that's a joke), I drove it hard on 3 occasions without a problem. I guess the boot from Sunbeam Specialties wasn't the answer for my car. For now, the boot and trim ring are just sitting on the tunnel and it really looks just fine. On to the next problem and challenge. thanx guys. steve

DanEC · #8 (**permalink**) 10-09-2016, 04:43 AM

Quote:

Originally Posted by steve meltzer

The day before (Thrs) I was scheduled to take the car to the guy to rebuild the shifter, I took all of the screws that retain the boot ring to the tunnel, completely out, not just loosened a few turns. And, viola (that's a joke), I drove it hard on 3 occasions without a problem. I guess the boot from Sunbeam Specialties wasn't the answer for my car. For now, the boot and trim ring are just sitting on the tunnel and it really looks just fine. On to the next problem and challenge. thanx guys. steve

Steve - here are a couple other things you can consider trying:

Before I bought my Sunbeam Tiger boot I made a vinyl boot from a pattern. I used wire from a coat hangar to form the outside circle that secures it under the trim ring. It applied 0-pressure one the shift handle. Looks were sort of up to individual opinion.

Since I installed the Sunbeam Tiger boot I haven't had any 3rd gear pop outs. However, I noticed that because the bend in my shift handle is pretty low above the top of the tunnel, the boot tended to ride up and forward quite a bit in third gear and was still obviously putting some pressure on the shifter. As a precaution, I pushed the boot down low and wrapped 6 or 7 wraps of black electrical tape around the handle right above the boot. It keeps the boot from riding up and the vinyl looks like part of the boot. Here is a picture of this.

steve meltzer · #9 (**permalink**) 10-09-2016, 06:56 AM

Dan, thanx so much for your thoughts, pictures and ideas. After I complete a few other projects, I'll get to this. For now, i'm just glad I don't have to any serious tinkering. steve

1985 CCX · #10 (**permalink**) 10-09-2016, 07:20 AM

Do not use synthetic #1.
Mike Miles is s great resource for all things 4 spd.