Loading

Replacement shift cable end for 1996-2002 Saturn SL/SL2/SW/SW2 manual shifter

by delsydsoftware, published

Replacement shift cable end for 1996-2002 Saturn SL/SL2/SW/SW2 manual shifter by delsydsoftware Dec 17, 2012

Description

Saturns are notorious for having issues with the manual shifter. Most of these problems revolve around a little rubber cap that holds the shift cable in place. A few solutions were offered in the aftermarket, including a steel bushing that was for sale on eBay for a while (and may still be).

The steel bushing corrected the design issue, but introduced another issue. It has a tendency to put so much torque on the shift cable that the plastic end of the cable breaks off. This is a huge problem, because it means buying a $200+ cable and spending a few hours installing it, only to have the shift cable end pop off again.

This happened to me a few years ago, and I decided to re-attach the broken end by drilling a hole in the steel cable and attaching the old cable end with a bolt and nut. (see saturnfans.com/forums/showthread.php?t=122577 for the original discussion). This fix worked for 4 years, until the shift cable failed at another place.

After replacing the shift cable, the end popped off again. This time, I decided to design and print a replacement. My model is significantly stronger than the original, and seems to improve the feel of the shifter as well.

More from Automotive

view more

Liked By

view all

Give a Shout Out

If you print this Thing and display it in public proudly give attribution by printing and displaying this tag. Print Thing Tag

Instructions

Print the part off with 100% infill. I used Makerbot Nuclear Green, since it is fluorescent. This allowed me to use a UV light to check for wear on the linkage when I was testing it (see the picture of my hand covered in nuclear green ABS dust and lit by a UV flashlight). If you do not have the steel bushing kit I mentioned before, you may need to scale this model up or down slightly to fit the original rubber bushing. I haven't tested it with the original bushing.

Sand the inside of the eyelet smooth with 320 grit sandpaper. Drill a vertical hole in the shift cable end, about a centimeter from the end of the cable. You don't have to make the hole too big. The end of the cable is hardened steel, so you will probably need a decent bit to get through it. A cordless dremel is strong enough to do the job, with a full charge. Attach the eyelet with a bolt mounted in the top of the eyelet. You don't need to use a nut on the bottom, since the position of the eyelet in the shift linkage will prevent the bolt from coming out.

Comments

You must be logged in to post a comment.

Top