I figured that since I lurk most of the time, that I would do something that would be more productive and somewhat informative.
This past Thursday, I replaced the joint that connects the shifter arm to the transmission. I know that there is a way to rebuild this, but since I was leaving on a 1800 mile trip in 6 hours, I chose to buy it from the local dealer.
Price was not too bad, $60 for the linkage and $2 for the roll pin.
Car: 1997 Outback 2.5 DOHC, 5MT transmission approx 175K miles
Long punches, (one wider than the pin and one a little smaller than the roll pin that attached the linkage to transmission) * I will look tonight at my set and get the sizes*
12" 3/8 drive extension
3/8 drive universal joint
3/8 drive ratchet
3/8" drive 12mm shallow socket
Needle nose pliers
Short small bolt just a hair smaller in diameter than the pin and only about 1/2 the length of the pin. (use this for alignment purposes)
Step 1. Jack up car and secure on jack stands
Step 2. Place shifter in 5th gear. This gives easier access to the roll pin that attaches the linkage to the transmission. When I started the process, I left the car in neutral and found it a real PITA to get the new pin installed.... The transmission cross member gets in the way to get a straight shot on tapping the pin in.
Step 3. Using the needle nose pliers remove the centering spring from the lower mount.
Step 4. Using the 12mm shallow socket and ratchet, remove the lower shifter arm nut from the transmission. Pull the arm off the transmission and lay off to the side.
Step 5. Using the extension, universal joint, socket, ratchet and wrench. Remove the bolt and nut that attaches the upper shifter arm from the linkage. On my car the bolt only went in one way so make sure you note which way it came out.
Step 6. Using the hammer and wide punch tap the pin up from the bottom until it is flush with the linkage. Then using the narrow punch finish tapping the pin out.
Step 7. Slide the old linkage off. Remove old centering spring for re-installation later. Note which way spring came off. It make a difference upon re-installation later.
Step 8. Get the new linkage and roll pin. Tap the roll pin into the linkage (making note of which way on the linkage faces down) just enough for the pin to stay in place. Too deep and you cannot slide the linkage on the transmission. I used a bench vise, but later I was able to tap it in with the hammer after I knocked it out a few times while installing it.( It was at this time I realized the 5th gear made things easier.)
Step 9. Slide the linkage on to the transmission. From the top of the linkage use the bolt to find the hole that the roll pin goes into. This will allow you to knock the pin back in without having the linkage flop all over the place. Since it is a bit smaller than the hole the roll pin should allow the bolt to fall out when the pin is knocked in. Using the wide punch and hammer tap pin until pin is equal length on both sides of linkage. Mine was about 1/16" exposed on either side. Reattach one half of centering spring to linkage
Step 10. Reattach the upper shifter arm using the items from step 5. Make note of bolt placement.
Step 11. Reattach the lower shifter assembly to the transmission using items from step 4.
Step 12. Reattach centering spring.
Step 13. Recheck your work and make sure you have all your tools.
Step 14. Raise car off jack stands and remove jack stands.
Step 16. Lower car to ground.
Step 17. Drive car and take in the new found shifting sensation.
If I left something out. Please feel free to add.
Edited by doc526, 30 June 2010 - 07:57 AM.