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Tips, etc, on rear shift coupler bushing replacement?

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Tips, etc, on rear shift coupler bushing replacement?

Old 08-23-2011, 01:06 AM
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Originally Posted by SeanR View Post
You are one lucky **** if you get a 90% removal rate. I freaking hate that job. I get about a 50% removal rate and had one that required the entire trans/TT taken out.
50% Yeah! So, law of averages says the GTS should be a piece of cake... right? :-)
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Old 01-04-2019, 12:37 AM
Michael Benno
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Default Tip for a stripped grub bolt

Here is a tip for extracting a stripped grub screw.

I decided to replace the bushing on my rear coupler. However, when I inspected the grub screw it looked pretty chewed up by someone's previous attempts to change it. I think they gave up.

I was able to hammer in a 4mm allen drive and put some pressure on it so I thought I would give it a try after I heated it up with a torch...

I made a heat shield using some 6" vent duct. I just cut off about 8"

I was able to drape the heat shield above the assembly. Here you can see my allen drive. It was stuck in there good after wacking it with a hammer so I decided to leave it in while heating.

Here you can see I am able to get fairly precise with the torch without concern of melting the undercoating.

Ok taking this pic while holding a live torch was a bit tricky. But it's for posterity!

After heating, I was able to put about 10nm of torque on the grub using the alien, but it just stripped out. So I had to resort to my bolt/screw extractor tools to get it out. Can you guess which tool I used?

Here is the Irwin cap screw extractor in action. To start it out, you tap it with a hammer gently to get the teeth to bit. Tapping it drives it in reverse so as you remove the screw it drives in the teeth.

Once I felt it had bitten I very gently started applying torque to the bit. I didn't want it to strip out. I would say it broke loose with about 25nm of torque which is a LOT

Here you can see the screw mostly out.

And voila! it's out. You will notice some aluminum bonded to the threads. That was some serious Locktite!

Anyway, I home this was helpful for you all.

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Old 01-05-2019, 09:07 AM
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great write up and photos.................sure to help many thx
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Old 01-05-2019, 10:23 AM
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Originally Posted by merchauser View Post
great write up and photos.................sure to help many thx
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Old 01-05-2019, 11:38 AM
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MB, great job and fantastic write up!

Reading it brought back my ham-fisted, hillbilly attempt at doing this same job, in which I may still have PTSD.
I will post a link here in the same thread for future generations that may need a salvage solution. When I read it, I forgot how many people helped me that week...
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