Jadz928

Tore the boot replacing the shift coupler. The cone point set screw is a bitch. Still haven't got it after much heat and Kroil. I'm going to let it set before I strip the screw.

I have to say that was a poorly designed component assy. The coupler does not need to be aluminum. What do they say about dissimilar metals?

Even the simple jobs can be a real PITA sometimes. Thanks for listening...

WallyP

Porsche can't win - first you bitch becaue the 928 is so heavy, then you bitch because they use aluminum whereever they can...

:-)

Jadz928

I'm not bitching about the 928 being heavy, I'm bitching because the job made me upset. Heck if Porsche were worried about weight, glass-filled nylon would do the trick in this application.

BTW, don't ask me how to get the boot pulled back without destroying it. Spent 1 hours before I finally went "snip".

Landseer

Do you want me to come over with the recip saw?

Jadz928

No Chris. I'm not out of it yet. I stopped before I messed things up. Still have plenty of meat in the screw to get it out. You know what they say, take a break before you mess things up real bad.

BTW, are you going out to KD for PM day? It would be nice to see you there. Will be there without Quinn because she is still too small. Plus there is much fun to be had by adults.

pscottjr

Jim, it is a PITA job. Spray heavily with PBlaster let sit. Then use a got long wrench to get leverage to get the screw out. Be careful not to strip the screw.

I had problems getting the screw reset into the correct location on the reinstall.

Have someone help you get the shifter in the proper gate as you tighten it back down. Don't use your wife, mine got it screwed up and I have to get back under to redo.....

Mr. Piff

Well it couldn't be as possibly bad as you think. I currently have a hole in between my rear seats because I couldnt get my set screw out. Either broken off or damaged by PO on his install, so I had to go in from the top with a dremel.

So I guess it is a good thing that I am a 928 lifer.

Good luck

dprantl

Yeah, I stripped that one once. Spent hours cutting the coupler out. The new boot isn't too hard to put into place since it's new and is much more flexible than the old one.

Dan
'91 928GT S/C 475hp/460lb.ft

Jadz928

Mr Piff.
I feel your pain or may be feeling your pain even more, soon enough.

Tried some more heat and Kroil. No budge.

I'm almost tempted to leave the socket head un-stripped and relieve the threads with a dremel. Seems pretty tight in there for a good angle on the dremel. I can understand why Mr Piff went thru the floor. I would save that for a last resort only.

If I do strip it, might consider welding on a socket.

shmark

When I did it I heated it up with a little mapp gas, used a long socket wrench with a good allen socket, crossed my fingers, toes, eyes and anything else I could and then applied pressure gently until it moved...hoping it wasn't stripping but actually turning. I got lucky I guess. I think the key is a good quality allen socket that fits with zero play, and a long wrench where you can apply gentle, steady pressure.

And yeah the boot is a major pain in the butt.

Rob Edwards

My new boot is nicely split up the side where I tore it trying to get it into position. It's ziptied in place, so I've just resolved never to drive in the rain. Hasn't been a problem yet this year......

Daniel Dudley

I watched some of the boys over in Wilbraham take a power drill and reduce the old coupler to bits. I am fond of sawzalls and cut off wheels, but the point is to sacrifice the old coupler with out hurting the shaft. The drill worked well and was quicker than I thought it would be. I think that they were drilling out the material around the set screw.

Oddly enough, one of the other particpants lost a set screw on the way to the tech session, and they just happened to have a spare with the new coupler...

Jadz928

Good stories. It is good to read your experiences to help come up with a game plan. I bought a new coupler and set screw in anticipation this might happen.
This will be a good thread to document why this seemingly simple job can quickly turn into a real PITA.

Will take pics of the extraction whether is comes easy or hard.

cold_beer839

Jim,

I have also discovered that most every little job on these cars is a PITA.

I feel your pain.

JKelly

I haven't messed with the rear coupler in a while, but iirc the boot is easier to get off of the coupler when the shifter is in either 2nd or 3rd. I think one of those gears makes it easier to push it back, but I can't remember......., it's late and I might be just dreaming .
Damn coupler

btw, why are you replacing the coupler?