915 shift coupler-welcome me

[911SCfanatic]

Hi. My name is Bill and I have a 915 that shifts like crap.
I am now officially a member (if you'll welcome me into your club) of the people that have been annoyed by their transmission shifts but only recently got around to doing something about it.

Yes, I know, there is nothing new in this thread. But after I have read about 100 similar threads, dammit, I want to be acknowledged as a member too. So...here is my grossly neglected, rattling, POS shift coupler bushings. Laterally there's almost 2mm clearance and at the ends there's about 1mm clearance. It's as sloppy as a...well, I can't tell the rest of the joke on a family BBS.

At the same time I'm upgrading to a short shift kit. Yes, I know my transmission will blow up within 100 miles as a result and the Porsche world may end as we know it, but I'm feeling reckless. Found good threads on loosening up the tolerance between the fork and shift lever to make it a little looser.

I'm replacing my transmission mounts and all of the shifter bushings too. One thing that is really chapping my a$$ right now is that 2 years ago when I bought the car I paid a mechanic $220 to replace what I thought to be all of the shifter bushings. This was when I was wet behind the ears and didn't know squat. I looked at the invoice and he only replaced the easy ones and didn't touch the shift coupler. Yeah, thanks *********, that really helps in a 915. The one that needs it most you leave alone. Brilliant.

[911SCfanatic]

[UTKarmann_Ghia]

Yep, I went through the same thing Bill when I first got mine. Mine also had alot of slop yet is not that hard to replace, so I'm not sure why your mechanic didnt do it.

[JP911]

My 915 was utter crap in first, second, and third. I replaced all of the bushings, put in Swepco tranny fluid, and shifted like a grandma, but it really didn't help. Finally, I broke down and had the thing rebuilt; new sliders, new 1-4 synchros, and a few other odds and ends. Now it shifts the way it should and no way in he11 am I putting a short shift kit on there that might decrease the longevity of the rebuild. The 915 trans was certainly not one of Porsche's strong points.

[Oh Haha]

Hey Bill, i have replaced ALL of my 915 bushings and had it rebuilt this year. Much better but still can be tricky sometimes. I think that mastering a pefect grindfree change is what makes for a good drive.
Where is oakland township? Near holly? i am near Flint and keep an eye out for fellow pcar folks when I am out.
See ya out there,
Wayne

[Jim Richards]

Hi Bill. I replaced my bushings last summer and replaced my shifter with a Rennspeed gate shifter right before a DE at Mid-Ohio. Shifting was vastly improved.

[rbcsaver]

911SCfanatic,
I've been there with my 84 Carrera. In my more 911 naive days I had the tranny rebuilt for 2nd gear syncro grinding, by a very "respectable" 911 shop. Since then, if moving more than 5 MPH, I can't shift into first without grinding. He convinced me at the time that it was because first was "too tall. I still live with that Bum's BS today. Money wasted. Be a truly informed 911 consumer, which is easier today thanks to sites like RennList and PelicanParts. He must have taken my 2nd gear syncro and put it on the first.
Also when asked then to replace the shift bushings he kinda blew me off. I have since done them myself. They "call" for a press to remove the shifter coupler bushing. I did mine myself by positioning maximum support for the alloy shifter, in a horizontal position over my bench vise. I lubed both sides with liq. wrench and/or equivalent. Heat on the alloy may help if the the center steel doesn't move. I tapped, then pounded Not Wailed on the hard metal center until it moved, then tapped til it was out.
I greased well, and replaced with new,
but was prepared to buy a new shift linkage if my experiment didn't work out.
One of the things for my eventual home shop will be a hydraulic press. They are essentially an upside down jack and not very expensive.
I purchased/used/ and truly recommend Wayne's "101 Projects for your 911," as a guide, but IMHO it falls short on many, many details.
regards,
Steve

[geof33]

Don't even WASTE your time doing the bushings in the coupler. It is a PITA and a new coupler is only 60.00ish dollars. You can even go Wevo, a bit more $$$ but either way the best way to go. Rebuilding the coupler wil most likely wind up with it being broken...

[Early_S_Man]

On the other hand ...

Changing the coupler bushings is very easy ... about a 30-minute job, with a large bench vise and two sockets ...

I guess it depends on experience level???

[rbcsaver]

AS I said, I changed mine without breaking anythiing and the cost was less than waaaaaaaaaaaay less than replacement.
regards,
Steve

[tmctguer]

i'm with early S man.............why not try to change the coupler bushings and use the money you save to put towards a tranny fluid change, a short shift kit (the P factory unit, IMHO), or even beer.

i successfully changed mine with little problem. adjusting the coupler took a few attempts, but it was worth all the effort.

[rbcsaver]

use the money you save to put towards a tranny fluid change

And, as I and many ohters have done,
use Swepco 201 Tranny Fluid.
regards,
Steve

[911SCfanatic]

Thanks for all of the comments/encouragement gents. Where I stand so far with this weekend's little project:

1) Short shift kit installed. Need to adjust fit between "fork" (box-shaped thing) and shift lever. Don't worry kids, I know better than trying to shift faster. I'll be safe and wear a condom. In fact I plan on shifting slower--the kit is just an ergonomic thing for me.

2) Shift coupler rebuilt. It was very simple--took only 20 minutes. I used my big-a$$ vice to press it out. Socket on one side and small socket on other side with portion of allen key to act as a punch. Thanks to all for providing the brilliant threads on this trick. For future people who might read this thread--don't believe the hype--it was EASY. The new coupler bushings are nice and tight.

3) New Swepco in the tranny...and I fell victim to the hype and installed a magnetic plug on the refill hole. Just used a long clear tube and a funnel. Reminded me of the old college beer bong days. Simple 10-15 minute fill (of the tranny, that is). Tried one of those oil hand pumps--it's in the garbage now. Over-engineered POS. Just let gravity do the work.

4) New transmission mounts. I found an error in Bentley's regarding a torque (yeah, me and everyone else) and ended up breaking a bolt. Had enough sense to realize the torque seemed too high and do a search on PP, but didn't have enough sense to figure it out and I just forged ahead anyway. trans mount bolt-got screwed by Bentley? That cost me an hour boon-doggle to the auto parts store.

Tomorrow: adjust shift lever fit and adjust shift linkage. Then, just drive.

[geof33]

I quess I need a bench vise... There are other threads relating far different experiences with shift couplers... Even Wayne's book suggests just replacing it. No big... So, new, or rebuilt... Hmmm...

[911SCfanatic]

Don't get me wrong about the coupler. I had a bead of sweat on my forehead because part of me was scared and the other part was really cranking on that vice. Once it let go, is proceeded to slip out. Really, using the socket method you have nothing to worry about because all of the load is placed on the beefy steel shaft (through the old bushings). Absolutely no load is placed on the aluminum housing, which IMO is what makes it fool proof.

[Randy Webb]

Don't forget to look on EBay - I got one for $25 - new. Cheaper than the bushings, alone so I traded my old one for a shift rod.

[911SCfanatic]

Completed the project and it feels AWESOME! Drove over 100 miles and it shifts incredible. I love the short shift too--definitely more ergonomic. BTW, marking the shift coupler position on the shift rod was useless for me.

Just like everyone else, I wish I would've done this project earlier.