Manual shifter mystery - Final Update - I'ts done

[SJ]

Thanks to all those that responded to my call for help.
Most of the ideas presented entailed getting your hands up there and using
some kind of pry device to press on the connecting rod and snap it onto the
ball joint.
One lister fixed his by wrapping a nylon web strap around the tranny and
over the connecting rod. He then ratchetted the webbing until the bushing
snapped into place.

Snapping the connecting rod onto the shift tube wasnt so bad, I used one of
them flat nail pullers. One end pressing on the upper inside of the body
tunnel. With that as fulcrum, I pulled down on other end of the pry bar and
the bushing snapped into place.

Snapping on the bushing on the starboard side of the tranny was not so easy.
Not of the suggestions worked. My arms and hands are not that skinny to work
up there. I had to drop the cat converter. Well . .it needed stainless steel
bolts anyway. The sawzall made quick work of that.

I still had a hard time because of the tight squeeze. I removed the vacuum
actuator that locks the front diffs. It has a leak in it . . .might as well
yank that out. Now I had room to play with. I tried using a similar approach
as before . .levering something against something. That didnt work. I tried
using a sliding wood clamp . .forget that. Hanging chains off a pry bar . .
.much cussing and several beers to calm myself down.

You have to be careful with that levering idea . . .the pushrod is right
above the connecting rod . . .its very easy to apply upward pressure on that
push rod and bugger up the push rod bushing and clips.

Finally I got a large screwdriver (13"), slipped it from the port side,
between the pushrod and the connecting rod, and out the starboard side of
the trans. I could see the screwdriver on both sides now.
I reached up, grabbed both ends of the screwdriver . .made sure that the
bushing was over the ball joint and the screwdriver over the connecting rod
end. .and pulled down. The bushing snapped into place. Praise be the Lord! I
sacrificed another beer to the gods.

I checked the shifter . . . nice and firm . . no slop in neutral . . tighter
than my wife's . .well . . never mind that.


SJ
85 Dodge PU, D-250, 318, auto
85 Audi 4k - - sold but still on the road
88 Audi 5kq
90 Audi 100q


----- Original Message -----
From: "SJ" <syljay at optonline.net>
To: <quattro at audifans.com>
Sent: Thursday, July 17, 2003 12:50 PM
Subject: Manual shifter mystery - Update


> Original problem: 88 5kq
> 1. flaky shifting into 5th
> 2. lots of play in neutral
>
> Latest news:
> 1. The nylon bushing in the connection rod(48) was shot. It was not even
> attached to the rod, but was laying on top of the transmission case.
>
> 2. I levered the other end of the connection rod off the ball joint using
a
> big screwdriver.
>
> 3. My local audi parts supplier had the nylon bushings in stock. The FA
> calls the bushing a  "ball socket". There is no item number for this part
> because it is part of the connection rod. But, the parts list shows the
> bushing as a un-numbered item listed underneath the connection rod. The
part
> number for the bushing is 803-711-279 E. The price for the connection rod
> with bushings is $40! . . .I got the bushings for free . . .had to fix his
> computer . . .but I think the bushings only cost maybe $1 each.
>
> 4. Getting the old bushings out of the connection rod . .and new bushings
> into the connection rod is easy . . .the nylon bushing is very malleable.
A
> little pushing with a large screwdriver was all that was needed. I put a
dab
> of white lithium grease inside the bushing.
>
> 5. Mounting the connection rod back onto the ball joints is a BITCH! There
> aint no room up there. This is where I'm stuck at.
>
>
> The bushing itself looks like those things used in windshield wiper
> linkages. You use big channel locks to press and snap the bushing onto the
> mating ball joint.
> On top of the transmission, there is no room for your hands much less any
> tools.
>
> I can get more room for my hands by taking out the port side tranny mount.
>
> I think I can get a pair of pliers to snap the bushing onto the ball joint
> on top of the selector shaft.
>
> But, getting at the bushing on the other end is a nightmare. I was
thinking
> of unscrewing the ball joint from the tranny and pressing it into the
> bushing outside the car. I would then screw the ball joint back into the
> transmission. Looks like enough room for a wrench if you can get both
hands
> up there.
> Once the back end of the connection rod is secured, I can snap the other
end
> onto the ball joint on the selector shaft with vice grips.
>
> Does anyone have any BTDT info on how to do this?
>
> SJ
> 85 Dodge PU, D-250, 318, auto
> 85 Audi 4k - - sold but still on the road
> 88 Audi 5kq
> 90 Audi 100q