by David Brockhurst
Date Added: Thursday 29 March, 2012
Hot gear knob, warm console, noisy- change the gear boot! Get the complete pack of upper and lower boots. Allow a couple of hours for the job. Take your time, don't rush, and be methodical. Unscrew the gearknob. Remove the console (mine is a mk2.5) - two screws either side of tunnel, two inside arm rest and one under the ashtray. Prise the electric window switch plate up with a small pallette knife - Very Carefully, then disconnect the switch. Pull the whole console slightly up and forward to clear the boot release. There will be some insulation wadding on top of the gear boot - set to one side. The upper gear boot can be unbolted (four bolts) and removed (mine was split). The lower gear boot is retained by bolts, before removing these note the position of any marks on the gear lever in order that the gear lever shaft can be put back the same way. Put the lever in neutral, unbolt it and carefully lift out. My lower gear boot was also split. The gearbox turret (seperate from the main gearbox oil) should have had soiled oil in it (mine had none) but if you have some, extract it with a small turkey baster and refil using new gearbox oil. Take off the old lower gear boot by cutting it with a stanley knife. Take off the nylon bush at the bottom of the lever. When refitting the new one, press hard. When refitting the lower gear boot ensure the circular nylon washer is on first before pulling the gear boot onto the shaft (a little grease helps the gear boot on). Refit it into the turret making sure it is in the right way. Refit the upper boot, put it all back together including wadding (refitting of all and console is reverse of removal) and you will notice an improvement in the smoothness of the gear change, the reduced gear and road noise intrusion and no hot gear knob! Wish I had done it long before - just take your time with the job.