shmark

Ok this has happened twice now. 4th gear, off throttle, and it pops out of gear and drops to idle. It's like there isn't quite enough travel in the shift rod to fully engage the gears. I've also noticed that about half the time, I pull it into 1/2/3 and it's like there's just barely enough travel to get it in those gears - the final "snick" it a fraction of an inch. But it hasn't actually popped out of those yet.

I got under the car this weekend to give things a complete look-see and the front cup is perfect, zero longitudinal play. I did have some looseness in the short-shift lever and added a rubber washer both top and bottom. Now that is very tight and the shifter is rattle-free. So I moved to the back and noticed a *very* slight amount of play in the coupler...and I mean slight, like barely noticeable. I did look into the records and the coupler was just replaced two years ago and only about 5000 miles.

Is it possible that the coupler is simply too far forward on the input shaft? That would shorten the available travel into 4th/2nd, which is where I've noticed the most difficulty. Anyone ever tried to adjust it in this way?

Vilhuer

There is only one correct position for coupler way its mounted to gearbox selector shaft. Make sure small screw which is holding it on one side is mounted correctly. Also check bolt on front end of coupler.

69gaugeman

What he said. There is a dimple in the shaft where the screw locks into. Can only be in one position

shmark

Ok makes sense. So why in the world would it pop out of gear? Any why does it feel like it barely engages a gear? The transmission is a new/rebuilt unit from 928 International, just a year ago.

Mrmerlin

check the rear shift coupler it is on top of the trans you may have to remove the exhaust and center heat shield and or the left side rear heat shield to do this, pull back the rubber boot towards the trans and loosen the clamping bolt , with a helper in the car center the shifter so it is not in any gear then retighten the coupler bolt, the coupler bolt sounds like it may have been loose enough to let the shift shaft move and thus not have enough throw to put the shifter in gear

Mike Frye

Erkka,

For the rear part of the coupler you're right. The 4mm conical bolt will only go in one place. However, I think MrMerlin is correct here, the front part is only a 13mm pinch bolt that can be put too far forward or back and also will adjust left or right. The way to do it (as MrMerlin says) is to have someone in the car to get the location correct while someone else is underneath to tighten it at the right spot.

It could be that part of the coupler (which doesn't require you to remove the heat shield (!)) or it could be something up at the shifter like part of the rubber shift boot piece or something else hindering your shifter.

I've been through every part of the shifter/bushings, until everything is right, it won't feel like you're getting closer. Just one part being fixed won't do it.

shmark

Thanks guys, that's basically what I suspected. It's the only thing I haven't done in the linkage. FWIW the rubber boot at the shifter is almost completely missing, just a "ring" of it left, on the list to replace. I've got tickets to the Monday night Falcons game tomorrow night, so it will have to wait until Tuesday to get back under there. And Mike is right, no heat shield in the way, very easy to get to actually.

Vilhuer

True, front of the coupler can be in any left/right and front/back position. Its partly used to adjust where selector is when lever is in neutral between 2nd and 3rd. If selector is not in correct position this is in wrong position. Its possible to have small conical bolt mounted wrong. It will start moving around. Even very little movent in rear will multibly at selector top end.

Fabio421

Mine does the same thing only in 2nd gear. I haven't tracked down the problem and have learned to deal with it by modifying my driving style. Please post your findings if you figure it out.

Mike Frye

Fabio and Mark,

I'm 99% sure the rear shift coupler is you problem. I had to adjust mine alone and I had to go back and forth many times to get it right, but it was clear after the first couple of attempts that the amount of adjustment at the coupler is amplified many times at the stick. My first attempt made it so that I couldn't get into 2 or 4 at all, subsequent ones were clearly just barely catching it. I can see where it would pop out if it were just barely engaged at the end of the range.

This is MUCH easier with two people and the owner/driver should be the one in the car because it's your choice where you'll be most comfortable.