Volvo M66 Shifter Cable Bushing

thingiverse

There is a bushing at the end of one of the two shift cables that drives the selection fork, on the top of the transmission, in my 2004 S60R with an M66 manual transmission. The bushing is very soft and has a little play in it, the cable can move slightly without driving motion in the selection fork. I wanted to remove the slop in the bushing to give me increased feedback during gear shifts. The rubber bushing can't be removed without destroying it, but the plastic center insert can be removed. I removed it, and roughly modeled it. I added 1mm to all outer diameters so that it would fit more snugly in the rubber bushing. The part was printed with polymakers CoPA. I recommend printing this in a regular nylon as it will hold up to any grease that you use on the inner hole on the bottom that slides over the pin on the selection fork, on top of the transmission. I would not recommend an abrasive filament such as a carbon fiber filled nylon. This model is basically a first draft, you may have to play with it, although, it is installed and working perfectly fine in my car. The ID of the hole that receives the pin on the selection fork should receive your attention. It was designed to be printed upside down. Many of the outjets received a 45mm chamfer to reduce the need for supports. The cutouts for the retaining pin are a little tricky to print, they need supports. I included a Cura profile with my print settings. Print with 0.1mm layer height if you can. Use at your own risk. Please note that clip in attached pictures is actually upside down.