broken main shift lever

[bobzinak]

My main shift lever snapped off at the to of the selector shaft ball. I would normally think this is an unusual occurebce. but I have driven this rover well over 250 thousand miles. This is the third time this has happened. It's not like I jamb and yank the lever..this time it broke off as I went into forth gear.. Causing me to shift from low to high range to get home..a pain to do properly...Due to time restraints I did not have time to wait for a new one to be shipped. Instead a 1/2 drill created a new hole in the selector ball and a liberal application of some JB weld epoxy and I was back on the road after it cured.. now it just may be me..but having three shift levers break off since i've had the rover seems excessive...has anyone else had a similar exprerience...not that I'm ragging on my 2A..if I were I wouldn't have kept this long...BOBZINAK......

[SafeAirOne]

I've had mine break. Mine is a 6-cylinder, RHD shift lever and it snapped about an inch or so above the pivot ball due to fatigue from the vibration of the diesel engine. I had it welded back together, but it snapped again at the same location about a year later.

Vibration must have been at just the right frequency, plus I THNIK the 6-cyl RHD shift lever is longer than 4-cyl shifters, so there's more leverage involved during the vibration.

I replaced the lever with a new one about 2 years ago and it's been fine so far.

[Jeff Aronson]

I've gone through 3 of them on my two Series II-A's over the 18 years of steady driving I've done on my Rovers. I'm guessing that it's just such a long shaft absorbing vibrations for a LONG time.

Jeff

[CliftonRover]

I have broken two, I plow 60 driveways every snow storm, I I do a lot of shifting, the shafts are hardened steel so welds do not hold as well, I have tried that too. I would just get a new one and try to shift easier. also check to make sure the selector shafts are not binding. they can get stuck or gunked up so every shift will be more difficult.

[Rineheitzgabot]

Had this happen today. Strange.

I was thinking of running a tap into the ball, and a dye of the end of the shaft. How deep is too deep in the ball? Will this work?

-Gary

[kevkon]

It's hardened steel.
Try slipping a tight fitting neoprene hose, like a heater hose over the entire shaft. It dampens the vibration and shock. It will also act like insulation.

[Jim-ME]

I have heard of this happening which is why I purchased a second one to have on hand. Does anyone know if a S3 shift lever can be made to accept the older style mushroom shift knob?
Jim

[Winooski]

Mine snapped at the ball as well, after the shop tech where I had the truck put her into reverse. They fabbed up a tubular sleeve that was welded to the ball, with the shaft of the shift lever inside the sleeve and then welded at the top end as well. Looks and shifts good now, but apparently not an uncommon problem. Glad it happened somewhere other than on the road, but I am going to purchase another for the inevitable next occurance.

[LR Max]

I broke one. Just welded it back on.

I'd suggest you do the same. Burn it with a 220V welder and it won't snap again

[ignotus]

Series III

I broke mine a few times in the 70's and 80's one just the day before my wedding in the homeymoon car! I finally had my work machine shop make one out of I think it was 5/8 round stock machined down to fit the ball. Didn't break that one.

[Rineheitzgabot]

Thanks guys. Guess I'll be welding it.

Gary

[mrdoiron]

Thanks guys. Guess I'll be welding it.

Gary

OK, so this now has me on a "defense in depth" plan... and will be adding "spare" to my list....

mike

[LR Max]

OK, so this now has me on a "defense in depth" plan... and will be adding "spare" to my list....

mike

Meh. Having a spare one around is nice but go ahead and weld that puppy up or it'll just do the same thing.

Once the retaining pin that prevents the shifter from rotating breaks...then you'll be wanting to install that replacement

[bobzinak]

I posted the orginal message in apr. 2009. I have since discovered more information, One article in LRW the writer said that he would always have a new gearshift lever welded at the ball. he said he had broken many of them. I have drilled the broken off part out of the ball. but just a note that the ball and selector end is VERY hard steel and will dull a drill quickly. this is just my opinion but you would think that a company that makes expedition vehicles would have designed a shift lever that you could stand on and not break. I feel sorry for the guy who has his shift lever break in the midle of some desert or moab hills and is stuck. the last time mine broke I was in forth gear and had to shift from low range to high range to get home..bummer..weld it! weld it! weld it!...bobzinak

[kevkon]

I think that's why they changed the design on the SIII. It needs dampening.