fraggle

I ended up pulling my transaxle to get that damn screw out. Hope yours goes smoother, it's tough to get your arms in there. Clean clean clean that screw and hit it with the pb blaster a few times before you start, because once it strips you're in trouble!

medipedicman

I have the coupler on the kitchen table, I have removed the old bushings, and have lubed everything up....however... I cannot remove the pin to install the new bushings.?.?.?

In the pics in previous posts show the pin removed.?.? I have gently tapped it but it does not budge.

Any helpful ideas or tricks???

I hope to get this back together tonight.

Thank you in advance

medipedicman

In Post #11 it shows all of the items numbered. It is item #2 and Item #3 that I cannot seperate. It is still inside # 4.......

Jadz928

Arbor press or a vise with an interesting combination of impact sockets

medipedicman

sigh.... Thanks Jim. I just didn't want to use force if not needed.

Jadz928

It's a press fit. Force is required.

medipedicman

I knew I kept those spacers around for something.

GregBBRD

Actually, the noise you mentioned makes me think that the gearshifter does move and it did try to get into 5th gear, but for some reason, did not/was not able to complete that exchange. You can drive the car at very slow speeds and shift it through the gears. What happens when you try to shift it into 5th, if you do this? Grinding, with the clutch in, would not be a good thing....which is what you described, in your OP.

medipedicman

Everything went back together very well. Observations to follow

medipedicman

Several thoughts on this job. The advice to treat the areas with liquid wrench or it's equal was well heeded. The grub screw was no problem at all.
There were two issues that I did not anticipate.
1. After the grub screw and the bolt were removed I was unable to remove the coupler. The forward rod had no play. I ended up using the shifter to put it in 4th and that moved the rod forward enough to easily remove the coupler. Perhaps that is common sense but it did take a few minutes to trouble shoot that issue.
2. After reinstalling the coupler with the new bushings I tightened everything up and declared victory. I then went to the cab to run through the gears. Reverse and 1st were WAY left. The console was very close to preventing me from finding them. Soo, back under the car to loosen the front bolt and turn the rod towards the passenger side. I over compensated and then had the same problem reaching 4th and 5th. I then split the difference and have perfect orientation. Much improved from the original orientation. It shifted smoothly through all 5 gears with the engine running, on jacks and letting the wheels turn.
Time for a test drive and a car wash.

medipedicman

Test drive results: I made it to the interstate and ran through the gears. When shifting to 5th I got the same result as before. It didn't want to go. I was able to throttle and double clutch and hit 5th. It held fine and accelerated great.

On decel, in 5th, at speed it made a terrible grinding noise.

To Greg's point, I think I have other issues. At a stop light or sitting in the drive way I can easily shift into 5th gear. Smooth as silk and the gear is engaged in the transmission. At speed though it is a fight. I hope that it will loosen up over time or I will develop a shifting technique that will minimize this as an issue.
OR
Someone will recognize these symptoms and share some knowledge.

Thanks for everyone's help. I never would have attempted this project if everyone hadn't been so quick to jump in with pictures and advice.
THANK YOU

Jadz928

Well done, Brian!

GregBBRD

Good job!

However, those bushings, while breaking up, are not "bad" in the plane that controls shifting from 4th to 5th.

It sounds like, from what you have said, you better get that "spare" gearbox warmed up. 5th gear syncro/engaging hub must be hammered.

medipedicman

Greg,
This has been bugging me since the test drive. Is there a fore/aft adjustment that can be made to help it fully engage 5th. It held 5th fine under acceleration but when I let off the gas it sounded and felt like it was trying to come out of gear. Not in a smooth "popped out of gear" way, but in a nasty grinding way.

1st and 3rd are fine. I understand those gears are on different rods, but by changing the fore/aft orientation to benefit 5th (maybe) I don't want to mess up 1st and 3rd.?.?.?.?

The top gears (R,2,4) engage with the shifter not quite to the top of the expected range of motion. I seem to have 1/2" or 3/4" of room on the shaft that tightens with the bolt. (post 11, items marked #1 and #2)

Just dreading having to open up the transmission. That would have to wait until Spring.

medipedicman

I have made what I hope will be the final adjustment. I moved the rod forward at the coupler. I am now able to engage all gears more smoothly than since I have owned the car. Unfortunately it does not want to hold 5th gear. I can engage it and using half gas or greater it holds fine. When slowing down, even for a minute it will try to grind out.
A local 928 friend suggested that it was a synchro issue.

Any thoughts?