Date registered: Mar 2013
Vehicle: 1971 220D
Location: Fincastle, VA
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DIY nylon bushings w/ common tools
There was a lot of play in the gear stick of my '71 220D even after installing bushings for the link rod down under, so I disassembled the shift housing and discovered a few remains of 2 bushings between the housing and the horizontal rod connected to the lever (1). Autohauz didn't carry such bushings, which I measured to be OD 21mm, ID 16mm. So I set out to make them... without a lathe.
I got 2 nylon spacers (1" x 1/2" x 3/8") at the hardware store (for $1.15). The 1/2" ID fit perfectly on a Dremel sanding drum (2).
Fitting the attachment in a drill, I used a bench grinder to get the outside diameter down to fit into the housing (21mm). Then removing the axle but leaving the drum, it provided an ideal guide for a 5/8" spade bit, which, thankfully is 16mm. It drilled beautifully until the spades broke through, so a Dremel grinding attachment finished it up. The third pic is before and after.
And the unit reassembled with the new bushing just visible between the rod and housing. (4).