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cegan09 · Joined: 03 Jul 2007 Posts: 71 Location: Mass

I'm starting to learn that there is no such thing as an easy task with this car. Time for my latest adventure.

I found what was wrong with my transmission, seems a link is broken in half. See picture below. However the tranny will still shift if you sit and move it from the broken link, so that makes me happy. The problem came when i tried to take out the broken link today. Got the set screw off, and i just can't get the damn thing to slide off the shaft. I don't want to pull too hard for fear of messing something up inside the tranny, so my only thought was a gear puller, that would allow me to pull the piece and not pull the shaft against anything in the tranny. I tried this and it didn't budge. For now i left the puller on there with pressure and soaked it in penetrating fluid. My Dad is going to add a little more force every other night or so and see if it will come free. So my question is the usual does anyone have any tricks that they've used?

Also, i need to get the other half of the broken piece out, how on earth do i do that. This is the part still attached to the linkage coming in from the shift lever.

There's a kid on campus that says he might have a spare of these for me, but in case he doesn't where do i find a new one? I believe it was Paul that showed me the short throw shifter like a week ago, unfortunately that listing got pulled from ebay. would this be the best replacement? Sorry for the long post and lots of questions.

Pictures from today.

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1987 Porsche 924s (summer project)

2002 Toyota Camry (practical daily driver)

morghen · Joined: 21 Jan 2005 Posts: 9102 Location: Romania

I'm not 100% sure on this but...i'm afraid that you might have to unmount the gearbox from the car to be able to remove that shaft.
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cegan09 · Joined: 03 Jul 2007 Posts: 71 Location: Mass

the last thing i wanted to hear was take out the transmission. oh well, if it has to be done it has to be done.

When i'm home again next weekend i'll poke around and see what i can find.
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1987 Porsche 924s (summer project)

2002 Toyota Camry (practical daily driver)

leadfoot · Posted: Mon Sep 10, 2007 4:03 pm Post subject:

Did a little investigating...
here is a picture from the haynes manual...
The lower section of the snapped piece has a split in the area that gets clamped.. alot like the steering column clamp... so insert a big flat blade screw driver and tap it in with a malet etc to allow the split to open up, it should just be a matter of pulling it off now with a gear puller.
The upper section of your snapped piece looks like it has a stud attached to the other side with a lock nut.
Two options here...
Either grap the snapped end with some vice grips and use a socket to get the nut off,
or grab the nut with some vice grips and drill out the snapped end so that you can pull the stud out the other side/nut end _ definitely harder option

Leadfoot
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Smoothie · Posted: Mon Sep 10, 2007 5:21 pm Post subject:

Whoops, that part was changed. Cegan09 would have the updated version that's not split at the bottom like that - it's solid all around with a setscrew instead of the clamping bolt.

I think if you're able to get a gear puller on it, then the job can be finished without removing the gearbox. Maybe try tapping on it after using the gear puller, then pull on it again, tap it again, etc. Plus, clean it off and use some PB Blaster or something on it.
Or, if there's room to get in there with a Dremel tool and cut it, do that.
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'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

924RACR · Posted: Mon Sep 10, 2007 10:07 pm Post subject:

Yes, use a puller, might need heat as well.

The other piece, as I recall there is a circlip on the other side of that shaft, or maybe it's just a nut. You should be able to feel it. Yeah, I think it's a nut.

PS - there should be no need to drop the trans to effect this repair.
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cegan09 · Joined: 03 Jul 2007 Posts: 71 Location: Mass

thanks guys. I have cleaned it off, i just took the picture first. I've got a puller sitting on it at the moment, and my Dad is going to tighten it a little each night. Hopefully the constant force will break it free.

I couldn't get a look at the back of the second piece, and i could determine what held it on by feeling around, which is why i was asking. I also couldn't find that assembly in the PET for the car.

The person on campus does have an extra of these parts, so as soon as i get it the car will be shifting again. That will be the first forward step i've made with the car so i'm excited. Now i just have to get a new gasket set and clutch so the engine can go back together.
_________________
1987 Porsche 924s (summer project)

2002 Toyota Camry (practical daily driver)