So let's say an idiot buys a 5-speed, and spends the holiday replacing the TT. Said idiot destroys the rear shift coupler allen screw while removing it, so he drills it out, installs a new coupler, and FORGETS TO PUT A DROP OF BLUE LOCTITE on the new setscrew.

Let's then fast forward, oh, to this morning, during a shakedown drive (following a shock R&R) where the shift from 2nd to 3rd (pulling shifter to the rear of the car) leads to a suddenly limp shifter and a car stuck in 2nd gear......

So do I have to drop EVERYTHING, or can I drop the exhaust and get access to the coupler without dropping the TT/rear suspension? I know I should just go look (duh) but work has this way of interfering.


Aye yi yi. At least I'm getting to know this car well!

 

The set screw is pointed and goes into a hole to locate the coupler on the shaft from the tranny. If you missed the hole with a generic set screw, then voila.
Plenty of room to get at it from under the car, It took me like 10 minutes to re-do mine with a newly ground point on the end. You have to get it in the hole...

 

You should be able to get in there with no problem. Mine doesn't have the dual exhaust, so I'm not sure how much room you'll have, but I think the gap on the passenger side is bigger. I was able to remove the heat shield on the driver's side without dropping the exhaust or even undoing the hangers.

I know all about that damned rear coupler and the set screw problems you ran into.

Now that it's new, you'll have no problems as long as you've still got the set screw. If it backed out, it may be a goner. Maybe it's still in the rubber cover though, so you might have gotten lucky.

 

We keep the set screws in stock I show 7 on the shelf in our warehouse.

 

Thanks Jim! The setscrew that is/was in there I got at the local True Value, I posted the size in a recent thread. I've gotta go to the hosptial today, perhaps I'll come by and pick up a spare 'correct' one.....

Never time to do it right, always time to do it again.

 

IMO that set screw shouldn't be substituted with hardware store stuff. It has a conical shape to match the shaft and is hardened. Anything else would be prone to loosening as the mismatched shapes settle, loctite wouldn't matter when that happens.

 

It is really not that hard to get to and do correctly. You do need the correct set screw to "hit the hole". I finally got mine in correctly after a little twisting, etc.

You may have to loosen the front part of the rear coupler that is attached the the shift rod to allow you to square up to the hole. This will also give you the opportunity to adjust the position of your shifter in the car. Mine was way to far over to the passenger side.

Also, be careful with that damn rubber boot. It is a PITA and can split.

Good luck.

 

Point well taken, I will defintely get the right part- the few times I've cut corners in the name of convenience (hardware store setscrew, Pep Boys' services, anything bought in a hurry on a Saturday) on this car I've been bitten on the ***.

pscott- hear you on the rubber boot, I put a new one on during the TT R&R and it was a major PITA with the TT out of the car. Not sure how I'll deal with it now.. It's a bummer 'cause I had it all aligned out of the car, now I'll have to figure it out in situ.

 

Rubber boot? Well now, I learned something new. My car doesn't have the boot and I suspect my coupler needs replacing as well. I'm going into it this weekend so I'll see just how bad it is. And it is easy to get to the coupler with the TT installed - I actually adjusted mine a few weeks ago and it was easy.

 

Real easy on the single exhaust cars harder 86 1/2 up .

 

Rob a few pictures would be great on the process and allow future searches on this subject. Thanks!

 

Will do. I'm gonna go visit Tom/Jim/Mark tomorrow for a setscrew, we'll see how it goes. Hopefully I won't have to drop the exhaust, but it comes apart pretty easy.

 

I saw the set screw on the "will call" desk earlier today and wondered when you would be in ...see you tomorrow !

 

aww, Jim sounds disappointed you didn't make it in there today.

 

Not many people actually stop by ...although Danglerb is here quite often.