986 5-speed shifter linkage bushing inserts - 3D-printed

flyingpenguin · August 6, 2021

Last week, on our way from Holland to Hamburg, I had to reverse into a slot at the gas station when I lost 1st/2nd and 5th/reverse gears. Carefully manoeuvring the hot exhaust and cats, I managed to attach a zip-tie to the detached linkage where the rubber insert had perished (old age?)

Gear 1 thru 5 selectable again, but due to the slop (both top and bottom) no reverse..

Porsche's official solution is an upgraded set of shifter cables (986-424-041-10) and linkage assembly (986-424-913-06) at a cost of over a thousand euros.

Recently acquired a 3D printer and started messing with tinkercad (a browser based basic version of autocad).

Came up with these inserts that appear to have fixed the problem at a cost of less than 2 euros in filament (PETG) and a couple of hours of my time.

Insert with socket for lower (8mm) ball joint.

Securing plate that gets glued to the backside of the insert.

Still had some slop in the whole linkage making it very difficult to engage reverse, so popped the upper ball joint loose, sliding off the securing clip. Rubber / plastic pretty worn, so identified the culprit slop.

Designed this insert that fills in the worn plastic and fits perfectly over the top ball joint (10mm)..