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OK, so you have removed the gear change selector because the gear change was stiffer than Ron Jeremy. Ideally, you shouldn’t need a hammer to change gears.
The issue is down to the pivot in the selector mechanism arm. See below, the original pivot is hollow and nothing more than a tube with the ends rounded over so it doesn’t slide out. As you can see, the mechanism around it is rusty AF which has seized everything up.
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix1.jpg)
You need to shave off the widened end to give the sleeve room to slide out. You’ll see more clearly in a while. I used a rotary tool with a carbide burr which made light work of the steel insert. You could also use a large drill.
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix2.jpg)
Flip it over and remove the lip on the other side. I used a step drill bit as it was quick and easy.
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix3.jpg)
You need to push the insert out. Remembering that it’s seized, it’s not going to slide out easily. I used a 10mm bolt…
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix4.jpg)
…and gave it a few taps to slide the insert out.
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix5.jpg)
Now you can see why the inside lip had to be removed. Space for removal is tight.
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix6.jpg)
With the pivot pin removed…
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix7.jpg)
…you can disassemble the mechanism and see the issue. Rust.
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix8.jpg)
Clean up the mating faces of both the mechanism…
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix9.jpg)
…and the arm.
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix10.jpg)
Grease all mating faces with a grease. Copper grease is ideal.
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix11.jpg)
To replace the pivot, we are using an aftermarket part for a totally different car. It’s a solid piece of machined aluminium which won’t rust like the pivot pin you removed.
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix12.jpg)
It’s available through eBay or Amazon. It’s for an R50 Mini.
Slide the new pivot into position. Again, grease it before installation.
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix13.jpg)
Push it all the way in and flip it over to reveal the pivot fixing thread.
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix14.jpg)
I would strongly recommend using thread lock fluid or even superglue on the threads to stop the bolt coming out.
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix15.jpg)
Apply the locking fluid to the bolt and tighten it into position. You don’t need to crank on it because the thread lock fluid with keep it in position.
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix16.jpg)
I made this insert myself so the bolt isn’t typical of what you’d get. In the kit linked above you get a high tensile cap head bolt and, for some strange reason, no washer. You really do want a washer since the supplied cap head bolt is smaller than the hole it’s supposed to be retaining against. Without a washer, the bolt will do nothing and the pivot will fall out.
![](https://www.evilution.co.uk/wp-content/uploads/smartengine/gearbox/454stiffgearchange/stifffix17.jpg)
Now let’s compare how free the mechanism is now.
Credit
Thanks to Phil from ww-smart-parts for sending out the seized gear selector mechanism.