Alright guys, I've got another question.
Currently I'm working on putting my 95 trans internals into an early '91 case because of this: Transmission Experts... Ever seen this happen?? (Carnage Pics)
I got everything in that thread fixed and I was putting it back together when I ran into a snag. The shift shaft nub that throws the shift rails is elongated and sets out further (towards the shift rails) on the 91 trans than the 2g shift shaft. This creates interference with the 2g shift rails and the 91 shift shaft. Also, if I use the 91 shift rails the hole for the 3-4 shift fork roll pin doesn't line up exactly.
I have thought of two possible solutions to this problem.
1. Egg out the roll pin hole on the shift fork so that the shift shaft can rotate enough to be in the proper position and use the 91 shift rails. I'm sure this is going to guarantee me a lot of slop in the 3-4 shift.
2. Pull out the 91 shift shaft and replace it with the 2g one. What this means is that I have to take out the solid "Impossible to get out" pin on the shift shaft somehow.
Here's my proposed solution to this. I'm thinking about drilling out the pin and tapping it to an M6x1.25 thread and threading in a long set screw with some blue loctite to totally replace the pin. Does anyone see any possible problems with this? Are set screws strong enough to take the abuse? This will also make serviceability a lot easier in the future.
Or what about drilling it out larger and throwing in a larger diameter roll pin from the hardware store?
I really don't want to buy a new shift shaft kit because for what I'm doing I'll have to buy both the 1g part and the 2g part to get everything I need to fix this.
So, what are your guy's thoughts on this?