Shift Cables for Manual 5 Speed (HELP)

I installed the shift cable but cannot figure out how the cable goes onto
the shifter. I was able to hoorup the three with the clips. How do I get
it on? Do I use a a pair of plyers or just push it on? I tried pushing it
on but it does not go on.

 

The shop manual advises using a pair of channel pliers.
This DOES work. I tried regular pliers, c-clamps and sheer
thumb pressure - none of those worked, but channel pliers DO.

The offset will allow you to position the grips around the
cable endcap and lever ball in a way that you can apply the
needed pressure to pop the cable end onto the ball joint.

My daughter's car recently had the cable end break loose while
the highway. This cable design is NOT very good when it totally
pops off and the driver loses shifter control. To prevent any future
problems on my daughter's car, I added a metal bracket to keep
the cable end in place should the plastic cap decide to break
again in the future.

At a dealership price of $260 for the cable set, I really expected
a better design. The parts counter guy told me the cable end cap seems
to break a lot during hot weather. One would think Saturn would have
improved this design, but why bother when there is a much better profit
margin on replacement parts ?

When it come time to replace the Saturn, my daughter will NOT be getting
another one due to this very bad shifter cable design - too much risk in
getting into an accident when the cable breaks loose.

Regards,

Ralph

 

My daughter had a similar experience. I can't believe that it's necessary
to replace the entire cable assembly due to premature failure of a small
plastic grommet. The Saturn parts department dismissed my complaint by
saying that failure generally occurs after 100,000 miles. But mine failed
after only 57,000 miles. Is there an after-market solution available that
would allow replacement of the plastic grommet only?

 

My daughter had a similar experience. I can't believe that it's necessary
to replace the entire cable assembly due to premature failure of a small
plastic grommet. The Saturn parts department dismissed my complaint by
saying that failure generally occurs after 100,000 miles. But mine failed
after only 57,000 miles. Is there an after-market solution available that
would allow replacement of the plastic grommet only?

 

More cases of this problem posted here:
http://www.chaosmagnet.com/blog/archives/000112.html

Suggested DIY fixes:
- Cable tie "zip straps"
- Drill out ball and replace with bolt
- Ace Hardware MP6258 plastic snap-in bushing

 

Couldn't get the suggested MP6258 bushing from Ace Hardware (actually a
5/8" nylon hole plug) to work -- too short. Fixed the problem by drilling
and tapping a small hole into the exposed end of the steel ball, and
re-inserting the original rubber grommet (both pieces, as it was broken in
half). Then, through a hole punched in the exposed end of the grommet,
secured with a screw through a large metal washer into the tapped hole.
Now, even if the grommet deterioates, the shifter cable won't come loose.

 

My failed too.

I fixed it as follows:

Drilled a hole in the ball.
Slipped cable over ball
Screwed a sheet metal screw with LARGE washer to hold the cable on.

It has been working for two years now.