Tighten up your Volvo’s shifter cable bushing with this 3D printable insert. For Volvo M66 6-speed manual transmissions found on the beloved 2004-2007 S60R and V70R. Replaces the factory shifter cable bushing insert to reduce play in the forward/backward motion of the gear selector. Installs in about an hour. Recommended to be printed with unfilled Nylon.

Background: If like me, you have set out on a mission to rid your Volvo’s gear shifter of fun-sucking sloppiness, this bushing insert may be the last piece of the puzzle. When I finally became fed up with the vague, spongy feel of my 2004 S60R’s gear selector, I installed a short-throw shifter and replaced all shifter bushings in the center console. The gear selector was greatly improved, however, there was still some forward/backward slop in the gear selector. Upon inspecting the shifter cables at the transmission end, I found that one of the cable ends was isolated from the transmission shifter bracket via a rubber bushing with a plastic insert. This rubber bushing has voids that are responsible for this forward/backward slop I was experiencing.
I have reverse engineered the insert and increased its outer diameter slightly to fit more snugly inside the rubber bushing. The reduced play in this bushing nearly eliminates forward/backward play in the gear lever giving you much needed feedback to ensure you are shifting comfortably and with precision.

Print Specifications: I recommend this be printed from unfilled Nylon such as Polymaker CoPA. Smallest layer height possible as it is a very small part.

Installation: This bushing insert replaces the bushing insert on forward/backward shifter cable bushing on the transmission side, in the engine bay, below the air filter box. There is a metal clip on the bottom of the bushing that retains the shifter cable bushing to a pin on the shifter bracket on the transmission. With the metal clip pulled out of its retaining position, the shifter cable bushing can be lifted off of the shifter bracket. The plastic insert on the shifter cable can be pressed out of the surrounding rubber bushing. The 3D printed bushing can be reinstalled in its place. It will fit much more snugly than the factory insert. The 3D printed insert’s bore can then be lubricated before reinstalling onto the pin of the shifter bracket on the transmission. The retaining pin can be slid back into place to retain the shifter cable bushing onto the pin of the shifter bracket.