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Issue
PT Cruiser's equipped with a manual transaxle have plastic inserts built into the shift cables that degrade over time, which result in extra slop in the shifter. The plastic inserts are not serviceable therefore once they wear out the cables must be replaced at a cost of more than $200.Solution I attempted to locate a replacement bushing through a few suspension manufacturers without success. So, I developed a successful DIY repair using a pair of rubber stoppers, washers and clips from Home Depot, which cost under $3. The stoppers fill the voids left by the degraded OE plastic inserts, and washers and clips ensure that the cable ends won't pop off (See photo, #2 below.). The repair resulted in reducing the slop in the shifter to a condition similar to when it was new. Tools & Parts Hand Tools, basic set Drill motor, with 5/16” drill bit Razor blade or Exacto knife 1 Stopper, rubber 15/16” x 11/16” 1 Stopper, rubber 13/16” x 5/8” 2, Washer, rubber, flat faucet 1/2" X 3/4" OD 2 Washers, metal, cut 3/8” ID 2 Hitch pin clips 1/4” Procedure I noticed that the inserts degraded after about 3 years on my PT Cruiser. Luckily, they're designed it in a failsafe manner; I've driven with them in this condition for the last 2 years. Finally, while putting off some work on the bike, the PT received some needed attention. 1. The air intake (air cleaner lid and box) assembly must be removed and the PDC (Power Distribution Center - fuse box) mount is unbolted to access the second cable end. See photo #1 below. 2. Drill a 5/16” hole in the rubber stoppers. I used a board which already had some oversized predrilled holes in it, which came in handy for holding the stoppers as I drilled through them.See photo #3 below. 3. To determine where to slice the stoppers horizontally insert each drilled stopper into the cable ends, mark them with the razor, than carefully cut them on the bench. See photo #4 below. 4. Now that we've created two new bushing (stoppers) it's time to install them. See photo #5 below. A. Once the new bushing (stopper) is in place on the right cable, add a metal retaining washer, which will hold down the cable. Then secure with a hitch pin retainer clip. (The pins on the shift levers are already grooved for retaining clips.) B. Once the new bushing (stopper) is in place on the left cable, add a metal retaining washer, which will hold down the cable. Then add an additional rubber washer above the metal retaining washer. I used a 1/2" X 3/4" OD flat rubber faucet washer, which I clamped and drilled to fit. Then secure with a hitch pin retainer clip. (The pins on the shift levers are already grooved for retaining clips.). See photo #6 below. 7. The completed installation. See photo #7 below.
Notes - I used two different sized rubber stoppers because the cable ends are two different sizes. Since the stoppers are tapered, they didn't have to be exact fits, so I just picked what seemed about right. Modication by Greg Edwards, from Texas. Additional Resources Manual Transaxle Guide
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