924Board.org

[MikeJinCO]

I have the Audi 5 speed. The problem is that the shift rod will not align with the shift linkage that attaches to the transmission. The transmission is bolted in and appears well aligned(I have the back deck cut out so I can operate from the top also). I have temporarily installed the shifter to help align the shifter rod but to no avail. Alignment appears to be off by a couple of degrees.

Any suggestions?

Yesterday I unbolted the tranny mounts so that the torque tube and tranny could move around, but that didn't work either.
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Mike


'67 MG Midget Dp
'71 Ocelot Dsr Kawasaki 1000(under rebuild)

[ideola]

Did you install a 5-speed in a car that originally had a 4-speed? If so, the 4-speed rod is longer than the 5-speed rod. You will need to source a shift rod from a 5-speed car. Any Audi-based 5-speed shift rod will do, including from 924S and 944.
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erstwhile owner of just about every 924 variant ever made

[MikeJinCO]

No , it is the original rod from a 1980 5 speed. I must have somehow bent it.
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Mike


'67 MG Midget Dp
'71 Ocelot Dsr Kawasaki 1000(under rebuild)

[MikeJinCO]

Pulled the shifter rod, easy as there is no motor in front. It is not bent. I have some sort of installation problem as using all the same parts from when it was removed, the Intermediate shaft(shaft that goes into the shift rod is flush with the transmission support beam, it must be at least 1" too high. I'll post pictures in the morning.
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Mike


'67 MG Midget Dp
'71 Ocelot Dsr Kawasaki 1000(under rebuild)

[ideola]

[Rasta Monsta]

+1, not really able to imagine how "degrees" come into it.
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Toofah King Bad

• WeiBe (1987 924S 2.5t) - 931 S3

[MikeJinCO]

it is a two part problem. First, the shift rod is not in alignment with the shaft it connects to on the transmission shift linkage. It appears off by a couple of degrees.

Secondly, the shift linkage on the transmission was almost in contact with the frame cross member ie the transmission is too high. I think I found that as there is no motor in front so the torque tube is fairly loose in there and the entire system is tilted. I jacked up the front of the torque tube and the transmission dropped down to where it looks much better. I will reinsert the shift rod and then support the torque tube and see what happens
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Mike


'67 MG Midget Dp
'71 Ocelot Dsr Kawasaki 1000(under rebuild)

[924RACR]

Oh, definitely, if you don't have an engine hanging off the back of it, the torque tube won't be sitting at the correct angle - it'll be a lot nose-up. I'd expect the front of it to almost hit the top of the tunnel... so if you put the shift rod in parallel to the tunnel, yeah, they're not gonna be co-axial... sounds like that's what you're describing?
_________________
Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

[MikeJinCO]

Finally got picture and on to photobucket. Got it down to being a problem of the shift rod shaft being very tight against the plastic tube that goes thru the tranny. Hence it won't shift very well. I have tries supporting torque tube in front(in engine bay) from full drop to high and tight with no noticeable change. To get the shift rod connected, I pulled it and cleaned out the coupling end and applied some grease. They easy way to get the tranny in place is to loosen the tranny mount bolts-3 8mm on each side side so that there is lots of wiggle room, get the trans mount bolts to the cross member started then progressively tighten everything up so that it finds a happy home.

This is a different view than normal as the deck is cut out so the view is from the top. the box on the right is the tranny support cross member that I boxed in with 1" sq tubing and sheet metal to add torsional stiffness. To the left you can see the cast fins on the bellhousing section and the plastic tube with the rod sticking thru it. The rod is tight to the top of the tube. I had the shift rod jammed in there once and had a minor broblem getting it out, it doesn't appear bent, but could be.


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_________________
Mike


'67 MG Midget Dp
'71 Ocelot Dsr Kawasaki 1000(under rebuild)

[kevingross]

Don't know what transmission you are installing, but judging from the photo it is not a type 016 five-speed built for the 924 / 944 series cars. What code is stamped at its top?
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Kevin
Catellus Engineering, Inc.
http://www.catellusengineering.com/
catelluseng@gmail.com

[ideola]

It looks like a standard 016 to me.

What I would do is:

• support the trans on a trans jack
  
• completely remove the mounting brackets
  
• remove the shift lever
  
• lower trans and torque tube assembly as far down as possible such that the torque tube is resting on the front-of-tunnel and mid-tunnel brackets, as well as the torsion carrier
  
• maneuver the trans jack up or down as necessary such that the torque tube is completely square and "free resting" on those three points I referenced
  
• disconnect the shift lever from the torque tube and from the shift rod
  
• ensure that the shift rod is passing thru the black plastic tube and connected properly at the gear selector input shaft (on the trans)
  
• re-install the shift lever, and validate that everything is moving freely with no binding on the black plastic tube
  
• If it binds, then the shift rod is bent, or there is an issue somewhere in the shift lever, shift rod, or linkage at the gear selector input shaft.

Once you have that all sorted:

• place a wooden block (a small piece of 2x4 is usually perfect) between the front-of-tunnel bracket and the torque tube
  
• slowly raise the transmission jack until the entire assembly is once again level
  
• the trans-torque tube eassembly should now be balanced, and sitting only on the front of the torque tube and the transmission jack
  
• re-verify that the shift linkage is all still bind free
  
• put the brackets back on the trans, raise the trans until you can screw the four big bolts in that attach the trans to the chassis
  
• with the trans still supported by the jack, get the bolts just threaded in enough that they'll stay in place, but the brackets aren't yet cinched tight to the chassis
  
• recheck linkage
  
• torque brackets
  
• Recheck the linkage
  
• If something binds now, then there is something wrong with either brackets or the chassis.

_________________
erstwhile owner of just about every 924 variant ever made

[MikeJinCO]

Thanks, I will try this. Have done similar several times, but one tends to get into repetitious habits so a different procedure can be quite helpful.

Kevin is correct it is a XT 4 speed from a 1978. I paid $350 for this rig thinking but not verifying it to be a 1980 but it is a 78(obviously there is no title). The only reason I would have preferred an 80 would be to get the 4.11 differential rather than 3.88. My main requirement was to get the modern adjustable rear suspension. I did manage to install an 8 gal ATL fuel cell behind this tranny, the 5 speed is about 4-1/2" longer and I have about 2+ inches clearance. Putting a fuel cell on the side is just as tight.
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Mike


'67 MG Midget Dp
'71 Ocelot Dsr Kawasaki 1000(under rebuild)

[ideola]

OK, now I'm confused.

[MikeJinCO]

Welcome to confusion. Apparently I have a 1978. I never bothered to check the VIN until yesterday and it is 9248++++. I got curious and found the XT#### stamp on top of the bellhousing casting a day or so ago and looked it up in Haynes.

The shift rod is the same one as was in it when purchased.

It shifted ok before I took the transmission out when we rolled/towed it down the hill to get it in the garage as that was my way of parking as there were no brakes. .

I also have on hand a 944 shift lever and shift rod along with torque tube and tranny so I'm going to compare the shift rod and lever just to see what the difference is.

Thanks for your help on this.
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Mike


'67 MG Midget Dp
'71 Ocelot Dsr Kawasaki 1000(under rebuild)

[924RACR]

If it helps... note that the difference between the 4-speed and 5-speed (non-snail) shift rod is just length (as far as I've noted)...
_________________
Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype