Trapped In a Tunnel - Cracked Shift Rod

[majhopper]

I installed new shift bushings last night and it was a breeze thanks to 101 Projects For Your Porsche and these forums. Thanks Wayne and All!

Who knew what you could do with a couple of sockets and a woodworking vise when it comes to pressing steel pins at 2:30am.

Anyhow, everything went fine, until I was re-assembling. The forward end of the shift rod has a small crack in it where the smaller rod comes out of it. Because of the crack, and whatever forces caused the crack, the end of the **** rod there is sort of mushroomed out, making it impossible to slide the new bushing (the one on the hanger) over it.

I went back to the old bushing (which was actually in good shape) and incrementally opened it up with an abrasive drum until it would go.

I did this because I saw only two ways to get that rod out for machining and welding. I don't like either one.

Even with the wallowed out bushing there, it is tight now, a 200% improvement over what I started with. It's a whole new car with third gear. A hose clamp is holding the end of the shift rod together now. I don't fear it will fail anytime soon but I really want to do this right.

There is some sort of sound deadening material in the forward end of the tunnel - is there access to freedom behind that?

How do I get this thing out?

Thanks in Advance

[Danny_Ocean]

"Search" is your friend:

911 912 Shift Rod Removal

Shift rod woes

Shift rod removal

Seems to be two camps...one says drop the motor the other says no. Based on all the other issues you're having, I'm guessing you'll have to drop the motor eventually anyway. Drive the car as-is until you get to the part where you have to drop the motor and repair the shift rod then (along with all the other "while I was at it" repairs).

[randywebb]

"two camps...one says drop the motor the other says no"

- that might be based on what year car and thus how high the stuff on top of the motor sticks up to interfere with pulling it out. You did not post what year car you have - it is likely easier with a 1960's or early 1970s car. I have only removed one with the motor out of the car, but you could try the so-called 'partial' engine drop (also has threads in the search engine). If that does not work, then you might have to go all the way.

If so, that is a good time to clean up the engine comp. & maybe reverse the bolts on the trailing arms (depending on year), replace old worn bushings back there, & etc.