Not changing

I have recently converted my Citi Shuttle '96 1.3 4spd to a 1.8 with a 5spd gearbox. The engine was bought from JapTech motors here in South Africa, we removed most things and basically just used the block and the gearbox. After a bit of fiddling, and replacing the flywheel with a 1800 one, getting a new clutch kit, and replacing the CV joints, as they were slightly bigger than the ones from the original 4spd gearbox.
Anyway, down to where I need assistance. Everything works fine and the car goes like the clappers. But I cannot engage 1st or 5th gears, we had to make the linkage slightly longer, as the orignal was more or less just straight across. Yet with the new 5 spd box, it was higher up, and it seems our little mod isn't working.
Help!

Hello en welkom hier…

The linkages on the 4 and 5-speed 'boxes are mostly the same except for one (the important one) shown below. Top one is the 4-speed linkage and bottom one is the 5-speed linkage, the 5-speed linkage is longer to provide more side to side 'throw' to accommodate the 5th gear. After you've fitted this and you are still battling to select gears you need to adjust the splined bit under the steering rack. You get a tool that assists you in doing this but if you've got an extra pair of hands you can do it without the tool. You basically need to adjust it so that you've got equal side to side play in 1st and 5th gears. To get a base line setting, stick both the 'box and the gear lever in reverse and tighten the clamp. Take it from there then, move it one spline at a time in the right direction until the gearshifts are smooth.



If you are handy you can throw together a set of linkages like this, it allows you to adjust your gearlever position (side to side and front to back) on the linkages itself. Friend of mine make these sets up but unfortunately it costs more than what most folks are willing to pay…

Dear Torker
Thanks for your response, and looking at your first pic, it becomes quite obvious that this seems to be the problem and hopefully the solution.
I have gone to "GoldWagen" and they do not stock this part, my question to you, and I sincerely hope that you can assist. Would you know where I can source this part in or around Johannesburg North.

I bought one from Volkspares in Jetpark before, some spare shops stock these as well but I think the best bet would be a scrapyard, there must be 100's of Citi Golfs waiting to donate some spares…

Yea everything that he (Tonker) says. You should be able to find it from any scrapyard real cheap.

Like your linkage setup there Tonker.    Think I might borrow the concept and make myself a set of those.    

Who in Joburg is pretty adept at getting the gears to engage smoothly. As we added a bit of flat bar to the gear selector arm. I now have 1st & 5th gears, but one can now accidentally either go into 1st or reverse. 

I don't know who you can go to in JHB, if you are willing to travel to Benoni I can refer you to a guy there, he does all my engine building and tuning. (If you get reverse when looking for 1st it means the ajustment needs some fine tuning)

Torker,
Where about is he in Benoni, and how much would he rush me?
Bear in m ind that I am unemployed, and we have had to do a few "Boer maak 'n plan", and almost on the extreeme limit on the credit card.