I am in the process of replacing the upper and lower gear shift rubber boots/gaiters on my six speed 2001 Mk2.5 and generally inspecting and rebuilding the gear shift mechanism.
1. The gear turret has two metal locating pins which prevent removal of the plastic bush and wavy washer underneath them. They do no appear to unscrew. How do I remove the bush to inspect it?
2. On the five speed version there is a small plastic bush which fits into the slot on the upper ball on the gear stick and engages with the locating pin. Is there supposed to be a pair of similar plastic bushes for the locating pins on the six speed version? There were none in mine.
3. I found that my upper wavy washer had split into two halves. Is this washer essential? It would cost almost £10 including carriage to order a replacement wavy washer, although I could order a full set of bushes, washers and shims from the same supplier for about £18.
I came across an excellent video on you tube describing this procedure - posted by a professional mx5 shop… afraid I no longer have the link, but I’m sure a google or you tube search would yield a result! Good luck with the job!
I bought the complete service kit frpm Moss for £61.95 incluing P&P. This kit includes upper and lower boots, upper and lower bushes and wavy washers and the nylon cup.
Once dismantled, I came across the two locating dowels. They are a push fit and then peened in place. I was concerned about how I would re-peen them when re-inserting so I decided to leave the lower bush. My plan was to try and see if I was happy with the feel of the box. If not, then go back and do the lower bush.
I’ve only driven about 20 miles since doing it but the gearbox feels like new with no play at all.
Sorry, I didn’t answer the question about the wavy washer. I would say it was fairly important. It puts a downward pressure on the bush, holing it against the ball of the gearstick
I think I’ll leave the two pins and lower bush in place too. I have already ordered the upper and lower boots (in silicon) from Dr MX5.
Moss no longer supply the complete six speed rebuild kit but only have the five speed on their website. They sell a separate six speed complete bushings replacement kit without the rubber boots/insulators at £43 + postage.
I have opted just to buy one wavy washer from Autolink to replace the top broken one and I will keep my existing plastic bushings.