help, gear shift went all noodley

g sturgill · 06-09-2011, 04:15 PM

I seem to have lost 2nd and 4th gear in my 73 911. The gearbox, I believe, is a 915. The shift lever doesn't want to pull back far enough to engage 2nd or 4th, and suddenly the lever itself feels very loose. Could I have broken something? It happened very quickly.

Help/thoughts appreciated, gary

Flat Six · Flat Six's Garage

Shift coupler bushings, I'd bet. Check in access panel between/behind front seats. Bet they're toast. R&R. As long as you're doing that, replace shifter cup bushing and shift rod bushing in tunnel between seats.

Plenty of threads detail the diagnostic, replacement, reassembly, and adjustment processes.

Good luck

Dale

70S Targa Guy · 06-09-2011, 04:59 PM

Quote:

Originally Posted by Flat Six

Shift coupler bushings, I'd bet. Check in access panel between/behind front seats. Bet they're toast. R&R. As long as you're doing that, replace shifter cup bushing and shift rod bushing in tunnel between seats.

Plenty of threads detail the diagnostic, replacement, reassembly, and adjustment processes.

Good luck

Dale

+1 on what Flat Six said. I could not shift into 5th gear at all. Below is a pic of what my coupler looked like upon removal. The bad coupler is on the right with one of the bushings totally gone. New bushings in coupler on left ....Toughest part is taking the pin out of the coupler to replace the bushings. Obviously, as you can see by the pic I failed and cracked the coupler

. Unless it's a simple issue of adjusting your shift coupler due to the coupler's clamp and/or set screw coming loose, yours will probably look similar. FYI, this weekend I plan on posting a step by step tutorial of my bushing replacement with lots of pictures.

LakeCleElum · 06-09-2011, 05:46 PM

+3......In my '73, they went TU overnight.....Thought I was into big coin.......Did the coupler and cup bushings for about $25 in parts.......Was in Tall Cotton again.........

g sturgill · 06-10-2011, 07:06 AM

Hey Targa guy,

Pulled the cover off the trans coupler this morning and you were spot on. There were no bushings left, just ground up plastic. Ordered replacements from our host.

How do I remove the center pin? Just press it out from either side? Anything I should be especially careful of?

Thanks, gary

r_towle · 06-10-2011, 07:28 AM

yes, you press the pin out.
DO NOT put pressure on the outer aluminum housing.
Instead, put the steel shank into the vice while leaving the housing to float in the air.
Tap the pin out.

Rich

richard003@wind · 06-10-2011, 08:10 AM

I have had the pin come out before during a spirited drive.... Good thing I was close to my shop.

g sturgill · 06-10-2011, 08:36 AM

Rich, great advice. Pin came out with no problem. I suspect that was the easy part, right? Getting the pin back into place with the bushings inserted doesn't leave much room to get the shank into a vise without getting into the splines and not being able to put pressue on the aluminum will be tricky. Again, what do you advise?

Thanks, gary

r_towle · 06-10-2011, 08:56 AM

it can just bite enough in the vice.
You dont need much pressure with new bushings and a clean pin.

I used the vice and a socket that was smaller than the aluminum....but larger than the pin.
One side of the vice presses the pin, the other side is pressing the plastic bushing.
that was just at the end...
to start, you can almost do it in your hand with a small hammer to tap is in.

The housing will break if you push against it...so do everything in your power to resist that tempting way to solve your problem...

Rich

Flat Six · Flat Six's Garage

Quote:

Originally Posted by r_towle

I used the vice and a socket that was smaller than the aluminum....but larger than the pin.
One side of the vice presses the pin, the other side is pressing the plastic bushing.
that was just at the end...
to start, you can almost do it in your hand with a small hammer to tap is in.

Rich

That's how I did mine. Also, if you R&R the shift rod bushing (in the tunnel), soak the replacement bushing for a couple of minutes in a coffee cup full of hot water -- pushes in w/just pressure from your two thumbs.

HTH

Dale

haycait911 · haycait911's Garage

'noodley'......... I like that.

wavhitcher · 01-08-2012, 02:10 PM

Searching threads on this issue. My 1973 E shifter also went 'noodley'. No apparent issues in the bushings found in the tunnel behind the seats. When I move the gear shift lever it has a lot of play, particularly side-to-side, but the bushing does not move. I can shift, it is just so sloppy a missed gear or hitting the wrong gear is bound to happen. Up front, where the lever goes into the can, I don't see anything obvious. Ideas? Also, how does one remove the shift lever housing without cutting the carpet? Seems the bolts are deep under the tight carpet covering the tunnel up front.

Thanks, Jeff

911pcars · 01-09-2012, 11:38 AM

Quote:

Originally Posted by wavhitcher

Searching threads on this issue. My 1973 E shifter also went 'noodley'. No apparent issues in the bushings found in the tunnel behind the seats. When I move the gear shift lever it has a lot of play, particularly side-to-side, but the bushing does not move. I can shift, it is just so sloppy a missed gear or hitting the wrong gear is bound to happen. Up front, where the lever goes into the can, I don't see anything obvious. Ideas? Also, how does one remove the shift lever housing without cutting the carpet? Seems the bolts are deep under the tight carpet covering the tunnel up front.

Thanks, Jeff

The gray perlon carpet is usually glued down. Remove the rubber boot, then carefully peel the carpet back to reveal the mount bolts (3) M8, (2) M6; 13 and 10mm sockets, respectively.

Shift into neutral, then pull the shift lever housing assy. straight up. Inspect the ball bush (45) and the shift shaft bushing (44), both are nylon and probably worn or perhaps in pieces. In some cases, the two-piece lever might be loose or actually separated.

'73-'86 on left, '72 and older on right

Let us know what you discover.

Sherwood

CCM911 · 01-09-2012, 12:33 PM

To get my pin out I removed the old bushings FIRST, and then was able to simply tap out the pin using a couple of properly sized sockets and a hammer. No big deal at all.

jstobo · 01-10-2012, 09:20 AM

If its not the shift coupler bushings, the pin holding the shifter to the ball may have broke. Your symptoms suggest that. Check the drawing and you can see where the pin goes #27 or 7. Good luck. My 69 does not have a pin. I had to get it rewelded when it broke after 42 years.

911pcars · 01-10-2012, 12:27 PM

Quote:

Originally Posted by jstobo

If its not the shift coupler bushings, the pin holding the shifter to the ball may have broke. Your symptoms suggest that. Check the drawing and you can see where the pin goes #27 or 7. Good luck. My 69 does not have a pin. I had to get it rewelded when it broke after 42 years.

Pin 27 breaking is possible but not probable on a 901 Sportomatic shifter. I should have labeled it as such in my post
Pin 7 breaking is possible but highly improbable (915 shifter)

However, to support your fix, in all cases, shifter separation is inevitable as the two-piece lever is assembled with epoxy with a duty life of approx. 25 + X years (X is variable).

Sherwood

bfunke · bfunke's Garage

Interesting - my pin was frozen into the splined part and I ended up mushrooming the pin so I just bought a new coupler. Be sure to get the 914 bushes as they are round not oval and will give you less slop. Best technique I've seen is to cut a block of Aluminum and drill the end fit the splined part. Put the block in the vise and then tap the pin out.

wavhitcher · 01-11-2012, 06:29 AM

Thanks everyone. Looking at this in earnest this weekend. I called the local P-car (independent) mechanic for his opinion. He expressed that the needed parts, whatever they might be, are difficult to get. If it is a pin I can maybe make one. Onward through the fog.

(BTW, my carpet is under stitched vinyl at the edges. looks original and it is in very nice condition for a 1973. It won't be nice much longer...)

wavhitcher · 06-04-2012, 11:13 AM

Ended up ordering a new short shift kit. The old stuff was worn out, including the metal that held one of the bushings. Not too happy with the shift feel now, however. At times it feels very stiff, like an over pressed bushing. I assume that will loosen with a bit of use (20 miles thus far).

A bigger concern is that the confidence in the shifting is gone. It was always easy to shift and have the right gear--now each shift has to be conscious. Any ideas?

Jeff

JQ911 · JQ911's Garage

I just changed the shifter coupler last Saturday thru the help of some Pelicanites. I also experienced struggle in shifting and downshifting. I could not be happier with my new shifter couplers. This made it easier for me.