Shift Coupler Bushings-How To Change

[Big Bad Bry]

I ordered replacement bushings for my shift coupler 88 5 speed but am not sure

how to remove old ones or install the new ones. There are 2 bushings one on

either side but cant see how they come out. Any suggestions would be welcome

Thanks

[m21sniper]

There are write ups on bannlist. Just do a forum search.

[Big Bad Bry]

Thanks sniper

[Xlot]

First remove the coupler from the shaft:

Put the shifter in 2nd gear
Undo the front bolt on the coupler that holds the splined section (13mm socket)
Hold the coupler in place and have someone shift the shifter to 3rd gear which pulls the shaft off the coupler
Then push the boot rearwards off the coupler - I wedge a spanner against the top of the tunnel to hold the boot in the rear position so I have free access to the set screw.
With the set screw exposed (its on the left side of the car), heat it up with a small butane torch - its loctite'd so heat is important in making sure you don't strip the hex socket
After you've heated the set screw up, use a 4mm allen-key to remove the set screw, and pull the coupler off.

Then its time to change the bushings:

Use a press and a couple of deep sockets to push the pin out the middle of the splined shaft. May be possible with a vise, but its pretty tight (spray some decent penetrating lube on the interface before pressing it out)

Then swap the bushings by hand.

On reassembly, put the pin in the freezer, and heat the shaft slightly with a torch, and then reassemble the press fit. With heat/cold, they'll go together a lot easier than pressing them apart.

Then reassemble, and don't forget loctite on the set screw. Also make sure you get the left/right alignment of the shifter correct.

All up its a pretty quick job - maybe an hour for the first time. Muuuuch easier than the front shifter ball cup