Transmission Control Shaft removal question

[Slahm]

I have opened my manual transmission, one of my spares, not sure if it is 1G or 2G, but I think it does not matter. I cannot seem to get the SECOND(closest to the housing) pin removed from the control shaft to slide it out. I am not even sure it is a spring pin. It looks like a solid pin, and does not seem to drive out. How do you remove the control shaft? I removed the other pin, which was a spring pin.

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Thanks!

 

[luv2rallye]

PM Twicks69 (tranny rebuilder).

 

[Slahm]

I have done that, any other people like to chime in? This one has me stumped, none of the manuals mention it, I guess they either never break, or are too simple to mention!

 

[twicks69]

Air hammer with a point tip. There is also the requirement once it is started that you rotate the shift selector arm so it clears the case and doesn't jam.

You just need to use the right tools.

 

[Slahm]

I got that out with a bigger hammer and a new drift, not sure why I didn't air hammer it other than not thinking and air hammer was an option on the internals.

I found the following, and have a question for you re: whether I can expect any wierdness....

The lower 3-4 shift rod assembly(not sure of the exact name) was broken by the lever being hit somehow, and had jammed. To solve this, I had to use a lower assembly from a different transmission, which I think was 2G, the original one I was fixing is 1G. I changed the lower assembly, as per the pictures below, and then found that I had to change the control arm, and the other two lower parts(I just exchanged the rods) to make a matching set. The depth of the slots in the shift rods lower parts was about 1mm shorted in the replacement parts.

Now all three lower parts and the control arm assembly match, and seem to work fine, but is there likely to be a different throw for shifting or not? I can probably take apart my spares until I find one with a longer piece and deeper cuts in the peices, but I don't know which tranny to open, so don't want to unless I need to.

Middle fork below is broken, piece is below it on the rag.

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[twicks69]

Well, now you likely have a 90 3/4 shift rail end mixed in with 91-99 rail ends, which will cause shifting issues with either the 90 shift selector or 91-99. You need to have a matching rail end.

 

[Slahm]

I am not sure what the shift rail and shift rail ends are, but the parts on the control arm, that I could not get the pin out, and the three rail ends(bottom of the rods) are matching. so basically I took the three whole rods and the control arm complete out of the other transmission, perhaps a 90. I will have to check the year. If nothing else, the whole set matches, and I figured maybe the shifter in the car would not...

The three rods were exactly the same, but I could not keep the middle one, as it was a modified Jacks rod with a second pin that is not(easily) removable. So I just changed the end on that one, it was the broken one in the first place.

So 1-2 and 3-4 FORKS are the same as were in the tranny. 1-2 rod and end are from second tranny, 3-4 end is from other tranny, rod is from the original(see above), and 5th rod and end are from second tranny, so is the complete control arm assembly.

ANOTHER way to say that is that the complete shift rail and control rod match, except for the 3-4 fork and rod, which I needed as it is the Jacks unbreakable one.

Thoughts?

 

[twicks69]

, it's not an "unbreakable" one; he uses an Evo 3 shift rail ground down to fit. I keep them on the shelf; they are not expensive at all.

 

[Slahm]

OK, well I was only quoting their selling point to ID the part for my question, as nothing in the world is unbreakable, ultimately. For the record, it is not just a ground down EVO shaft, it is double pinned, which is why the lower portion does not break off like all the others I have broken as the load is spread further up the fork, I assume that is why they call it that.

But that has very little to do with my question, any thoughts on the question I had? It seems from you response like you figured I have mixed ends, which I do not, and I am using the matching control rod. So you think that is an OK combination, or a no-no.

Thanks!

 

[twicks69]

So you have the matching shift selector and cage, and matching shift rail ends; are the shift lever arms the same? That will need to match to your shift cables. It sounds like you are now using the shorter 1990 shift rail ends? As for the shift fork and shift rail design, the key thing is the differences between the shift fork roll pin position -- was the donor transmission as well as yours using a 2-hole 3rd/4th shift fork or does the donor shift rail use a 3-hole 3rd/4th shift fork? The roll pin placement/angle is different on the 1992.5-1999 3rd/4th shift rail and cannot be used.

As for getting the fork off the one that Jack puts the 2nd pin drilled through the middle of the fork, well, that's easy. Use a cut wheel and cut a groove in the fork along a nice spot where you will then use a hammer and chisel and split the fork in half along the groove. Then you can remove the roll pin, and debur the shift rail and use it again by swapping the shift rail end.

 

[Slahm]

Thanks for the info, the 3/4 fork and shaft are identical to the donor parts, other than being pinned with their extra pin. The other forks and shafts seem identical as well, just the rail ends, and shift finger/cage are different.

The difference seems to be a deeper cut into the rail end, to accomodate a longer shift finger on the originals, and a shallower cut and shorter finger on the donor parts, which sound like they are from a 90. I am going to confirm that today, and maybe just get some from another 2G to make this easier all around.

It seems to work fine, on the bench, I am just worried maybe I will run into a shifter cable length issue or someting, but that being said, I have never run into that changing to a 2G tranny, vs a 1G, so I cannot imagine it will be an issue, maybe the cable bracket will need to be changed, and I really do not know how to ID which are which, I have many.

Is there an easy way to know which cable bracket go with which tranny?

Thanks!