924 trans drop: problems

[andrewwatkins]

I'm currently attempting to begin the rear main seal replacement on my '81 924, and I've barely started and run in to some problems.
First: Haynes says to pry out the ball end of the shift lever from the socket with a screwdriver. I have no idea what kind of screwdriver they might have used, but as far as I know no screwdriver will fit. No luck with a prybar either. Now, I have managed to scoot the selector rod forward next to it, but I'm not sure if it's far enough.
Second: I can't unplug the back-up light switch because the end of the selector shaft (runs across the top of the trans) is in the way. It's clearly different than the diagrams suggest, much larger. There's really no way to get a wrench or anything to the plug from the other side, as there's barely an space and no way to see the plug from that side. The selector shaft cover also appears to have another part of two to it, so I don't want to risk just taking the cover off.
Tips?

[John_AZ]

Hi Andrew,

Sorry, too many years since I worked on my early 924s.
I would post on the 924 forum 924Board.org :: Index
A few members on Pelican are regulars like Rasta Monsta.
GL
J_AZ

[kcoyle]

Yup, 924board.org.

IIRC your late 924 has the 944 transmission and not a snailshell. I've never dived into these waters before but this may help as well.

Transaxle - Checking, Repairing, and Replacing the Shift Lever and Shift Linkage

Transaxle Removal and Installation

Kevin

[ideola]

Here's the basic procedure.

1. COMPLETELY REMOVE both bolts from the driveshaft-to-input shaft coupler. REMOVE THEM COMPLETELY.
2. Slide the coupler back onto the input shaft. DO THESE FIRST TWO STEPS BEFORE YOU DO ANYTHING ELSE
3. Remove the rear section of the exhaust
4. Remove all 24 CV bolts and discard them, setting the half shafts aside for inspection, cleaning, and re-greasing (plan to get replacement bolts for the CVs)
5. Position transmission jack and support the trans
6. Remove bolts that connect the trans bell-housing to the torque tube
7. Remove the two bolts that hold the trans mounts to the chassis
8. Slowly and carefully lower the trans PART WAY, taking care not to bend the shift rod. You just need to give yourself enough clearance to get to the shift rod and the backup switch.
9. Completely remove the shift rod selector set screw and "jiggle" the shift rod off of the shift selector
10. Disconnect the spade terminals for the backup switch
11. Continue to incrementally lower and move the trans toward the rear of the car. The plastic sleeve that protects the shift rod will give you some grief, but with some gentle and persistent persuasion, you should now be able to completely lower the trans out of the car

[ideola]

Notice that you don't need to remove the shift lever ball socket thingy. I don't know why Haynes does this, but they often enumerate additional steps that aren't really necessary.