rjtw

This seems to be the month for minor issues cropping up -- I seem to be reaching the point where the few problems I experience with the car are from original components just reaching the end of their lives. It has otherwise been an exceptionally reliable car for many years!

I don't drive my '83 5 speed very much, it's pretty much a weekend toy. So I'm not sure when or how anything happened but I have suddenly woken up to the fact that there seems to be excessive side-to-side slop in the gearshift. I can still shift into all gears, and there is virtually no fore-aft play. But I must have two inches of left-right play (when in any gear) and it is not good. I haven't yet gone under the car to look at anything.

Is this a rear coupler issue? I found the following thread: https://rennlist.com/forums/928-foru...ust-arose.html

If so, it seems like this could be loose bolts on the rear coupler and/or worn out bushings in the coupler -- is this correct? Or is this possibly worn forks or some other serious issue with the transmission?

One more question -- are there any guides for the shift rod on top of the torque tube? I replaced a popped-off front ball almost a year ago (and all the little white plastic bushings under the shift lever, they're all still good) and I have a vague recollection of a guide somewhere for the mechanism. Could a worn guide be causing this slop?

Thanks!!!
Rick

Dave928S

Highly likely it's the rear coupler bushings causing your issue. You can either replace the complete coupler, or replace the bushings, which are much cheaper. Outside chance something else is loose, but I'd check the rear coupler first.

There is only one guide for the front shift rod, which is just forward of the shifter. It's unlikely that will have much wear.

SwayBar

Mine was caused by a totally destroyed front shifter ball cup bushing. Replaced it with a steel one from 928 Motorsports, and it's for my 89 GT racecar.

checkmate1996

+1 on the rear coupler - make sure the cone screw didn't back up..

Dave928S

He's already replaced the front ball cup and bushings ...

rjtw

As a followup, this was indeed the rear coupler. I ordered the complete rear coupler from the nice folks at 928 International a couple of weeks ago. Although I was dreading a messy and difficult job, I was in and out in just over an hour.

The most difficult part of the job? Getting the boot off the old coupler and putting it back on again after installing the new coupler! It took maybe 20 minutes of persuasion each way, but the good news is that the boot (still original) was not only in one piece but still in great condition. The dreaded lock set screw was firmly torqued in there but came loose immediately with a 4mm allen on a socket. I had to put the transmission in 3rd or 5th (this pulls the rod and coupler toward the front of the car) to get access to the set screw and also to leave enough room to push the boot back towards the transmission all the way. But I had to play a little game to get the old coupler out -- first engaging 2nd (pushing the rod coming out of the transmission all the eay back) then moving the shift lever aft all the way, pulling the shift rod forward. The coupler could then be disengaged. With a little further persuasion by jamming open the clamp at the end of the shift rid with a wide blade screwdriver to fully release the splined shaft of the coupler.

The only real issue I encountered was that the new coupler just wouldn't go onto the transmission side more than a quarter inch or so. There didn't appear to be any burrs on the inside of the coupler, it was just too tight. After trying to open up the hole using some emery paper on a dowel, I ended up breaking out the Dremel with a half inch drum sander attachment and VERY finely sanded the inside of the coupler. It took two or three tries (I was barely removing anything) until I got it to fit on... very firm but no slop. After that it was pretty simple to find the center of the detent for the set screw and put it all back together.

My son helped me on centering the gear shift again. It took two or three tries but wasn't hard to adjust the position of the splined shaft. I may go for one further adjustment, I want the stick a little further to the left, but it's minor.

And the best part -- it shifts GREAT again, possibly better than I remember for years! WOOHOO!

Attaching a pic of the old coupler. Sure enough one side's bushing was completely gone. The other side was intact but still more slop than in the new coupler.

Thanks for all the help and advice. The folks on Rennlist are awesome!

Dave928S

Good to hear Thanks for following up on the result ... often we don't hear.