Rear Shifter Coupler Boot - Don't Let it Beat Me
11-04-2011, 10:22 PM
#1
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Rear Shifter Coupler Boot - Don't Let it Beat Me
87 S4 5 speed.
I am unable to successfully get this sucker off! I can push it far enough back to reveal the 13mm bolt, but that is about it. I cannot get it past the shift coupler and after a full hour, my fingers are plain worn out. At 56, my hands just aren't at strong as they used to be..
For reference, I have good access to the underside of the car whereas I can position myself directly under the torque tube and get both of my hands on either side of the boot.
I don't want to cut the boot as it is relatively intact and not torn. I have attempted to put two stubby screwdrivers alongside the coupler in an effort to pry the boot back, but the screwdrivers are too short. The next larger screwdrivers I have are too long - so that doesn't work. I also coated the inside of the boot with a smear of grease in the hope that it would slide easier over the coupler - but no dice.
I've given up for the evening, but would like to go at it again in the morning and claim victory. Any helpful hints would be most appreciated!
I am unable to successfully get this sucker off! I can push it far enough back to reveal the 13mm bolt, but that is about it. I cannot get it past the shift coupler and after a full hour, my fingers are plain worn out. At 56, my hands just aren't at strong as they used to be..
For reference, I have good access to the underside of the car whereas I can position myself directly under the torque tube and get both of my hands on either side of the boot.
I don't want to cut the boot as it is relatively intact and not torn. I have attempted to put two stubby screwdrivers alongside the coupler in an effort to pry the boot back, but the screwdrivers are too short. The next larger screwdrivers I have are too long - so that doesn't work. I also coated the inside of the boot with a smear of grease in the hope that it would slide easier over the coupler - but no dice.
I've given up for the evening, but would like to go at it again in the morning and claim victory. Any helpful hints would be most appreciated!
11-04-2011, 11:20 PM
#2
Nordschleife Master
Spray the aft-end lip of it where it goes around the selector shaft with your favourite spray lube. Then with a gloved hand, grip it in the palm of your hand (like a tennis racket grip) and while pulling rearwards, twist it back and forth - it'll ride up and over the bolt with a few successive twists.
Then I wedge a combination wrench against the upper-forward part of the tunnel profile to hold the boot back while working on the grub screw, M8 bolt etc.
Then I wedge a combination wrench against the upper-forward part of the tunnel profile to hold the boot back while working on the grub screw, M8 bolt etc.
11-05-2011, 11:42 AM
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Thanks for the tips! I sprayed WD40 all in the boot, put my best pair of rawhide gloves on and grunted and groaned, twisted and hollered...and it budged little more than what I accomplished last night - which was essentially nothing.
I cut that sucker off!
There are absolutely NO bushings in the coupler, not even a vestigal piece. The remnants of the bushings had disintegrated into the boot.
Next up is getting the set screw out of the coupler. I have sprayed it with liquid wrench, going to wait awhile. If that doesn't work, I'll try a little heat.
I cut that sucker off!
There are absolutely NO bushings in the coupler, not even a vestigal piece. The remnants of the bushings had disintegrated into the boot.
Next up is getting the set screw out of the coupler. I have sprayed it with liquid wrench, going to wait awhile. If that doesn't work, I'll try a little heat.
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11-05-2011, 12:08 PM
#8
Rennlist Member
Thanks for the tips! I sprayed WD40 all in the boot, put my best pair of rawhide gloves on and grunted and groaned, twisted and hollered...and it budged little more than what I accomplished last night - which was essentially nothing.
I cut that sucker off!
There are absolutely NO bushings in the coupler, not even a vestigal piece. The remnants of the bushings had disintegrated into the boot.
Next up is getting the set screw out of the coupler. I have sprayed it with liquid wrench, going to wait awhile. If that doesn't work, I'll try a little heat.
I cut that sucker off!
There are absolutely NO bushings in the coupler, not even a vestigal piece. The remnants of the bushings had disintegrated into the boot.
Next up is getting the set screw out of the coupler. I have sprayed it with liquid wrench, going to wait awhile. If that doesn't work, I'll try a little heat.
11-05-2011, 12:30 PM
#9
Sorry if this is a stupid question, but which direction are you trying to move the boot? The front part should be pushed towards the rear. A couple of old metal shoe horns inserted on either side might help to get the boot slid back if you still need to move it.
11-05-2011, 12:51 PM
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Nope, not a stupid question. I was attempting to push the boot to the rear..
11-05-2011, 03:23 PM
#13
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FWIW, I heated mine plenty, in a couple of sessions, with a propane torch. I broke two Allen sockets in it. Tried to drill out the set screw. And eventually ended up cutting the whole coupler off with an angle grinder. Even after that, the remnants of the set screw were still fused into the shift rod, and I actually had to drill a new pit into the rod for the new set screw to seat in.
More recently, I spoke with one of the techs at a pretty well-known 928 shop. He said that he always uses his MIG welder to build up the set screw and maybe weld something to it to use to remove it. I'll probably try that on my next one.
Good luck on yours. Hope it's a lot easier.
More recently, I spoke with one of the techs at a pretty well-known 928 shop. He said that he always uses his MIG welder to build up the set screw and maybe weld something to it to use to remove it. I'll probably try that on my next one.
Good luck on yours. Hope it's a lot easier.
11-05-2011, 03:51 PM
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Burning Brakes
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Damn......!!!!.... Guess I got lucky with the '79.....
FWIW, I heated mine plenty, in a couple of sessions, with a propane torch. I broke two Allen sockets in it. Tried to drill out the set screw. And eventually ended up cutting the whole coupler off with an angle grinder. Even after that, the remnants of the set screw were still fused into the shift rod, and I actually had to drill a new pit into the rod for the new set screw to seat in.
More recently, I spoke with one of the techs at a pretty well-known 928 shop. He said that he always uses his MIG welder to build up the set screw and maybe weld something to it to use to remove it. I'll probably try that on my next one.
Good luck on yours. Hope it's a lot easier.
More recently, I spoke with one of the techs at a pretty well-known 928 shop. He said that he always uses his MIG welder to build up the set screw and maybe weld something to it to use to remove it. I'll probably try that on my next one.
Good luck on yours. Hope it's a lot easier.
11-05-2011, 04:23 PM
#15
Nordschleife Master
I've only had one that I had to drill out, I used a right angle drill and got through it easy.
Once out I rethreaded and replaced with a modified bolt.
All others have come with a little heat, be careful with the torch though, its easy to start a fire under there.
Once out I rethreaded and replaced with a modified bolt.
All others have come with a little heat, be careful with the torch though, its easy to start a fire under there.