200 20v Shifter Bushing Replacement

BLAKEnwURS · Post by **BLAKEnwURS** » Sat Oct 04, 2014 3:43 pm

Hey guys,

My girlfriend recently acquired a 200 20v Avant. When she bought it the shifter was borderline unusable. I traced the problem down to the bushing at the transmission end of the shifter rod. It was completely shot and had so much play im amazed the guy could drive the car at all.

I ordered the new bushing from 034 (http://store.034motorsport.com/products ... plica.html). I have removed the smaller cross ball joint part, and the set screw on the selector, but I cannot for the life of me get the selector part (with the ball) to slide off the transmission. I have soaked it in PB blaster and used a long rod from the other side of the transmission to try hammering it off but its not budging.

Am I missing anything here? I have already chipped the transmission case with my hammer technique and am starting to get frustrated. What is the best way to replace this bushing?

loxxrider · Post by **loxxrider** » Sat Oct 04, 2014 7:47 pm

Your trying to pop it off of the ball right? From my memory, I did it from underneath using my man strength and bare hands at some funky angle.

BLAKEnwURS · Post by **BLAKEnwURS** » Sat Oct 04, 2014 8:12 pm

I considered doing that. But what I am trying to do is slide the bracket with the ball on it off the transmission shaft. The part with the set screw type thing in it.

At this point I think I'm going to do it your way and pop the bushing off the ball. I was just worried about getting the new busing on correctly.

loxxrider · Post by **loxxrider** » Sat Oct 04, 2014 9:02 pm

Yeah, it's a bit of a bear both to get off and back on, but it'll go on, especially if you can get something to pry against it. I'm not properly envisioning your alternative method, but I haven't looked at that setup in a while. It's been a few years at least.

BLAKEnwURS · Post by **BLAKEnwURS** » Mon Oct 06, 2014 11:22 am

loxxrider wrote:Yeah, it's a bit of a bear both to get off and back on, but it'll go on, especially if you can get something to pry against it. I'm not properly envisioning your alternative method, but I haven't looked at that setup in a while. It's been a few years at least.

http://www.theprojectpad.com/viewtopic. ... start=3800

Towards the bottom of the page you had a picture with the ball arm thing off the transmission. How did you get that part off? I wanted to remove that part with the ball still attached to the shifter and pull the whole thing out through the inside of the car. Then use a puller to remove the ball, replace the bushing and press it back on.

But it seems to be rusted on or something so I have been considering dremeling out the bushing in the car and then prying the new one on. Just seems easier to do all of it outside the car.

yodasfro · Post by **yodasfro** » Mon Oct 06, 2014 12:55 pm

You really do need it out of the car to replace the bushing properly. You have to remove the crimped in retaining washer to installing the new bushing. Have you tried moving the shifter from in the car with the set screw removed? That might help free the linkage off the selector shaft. If not try a small puller of sorts like one made for battery terminals. Make sure you mark the position of the shift linkage where the two shafts join and are clamped together with the 13mm bolt before removing it from the car. Otherwise getting it lined back up without the factory tool with be a PITA.

BLAKEnwURS · Post by **BLAKEnwURS** » Mon Oct 06, 2014 3:49 pm

yodasfro wrote:You really do need it out of the car to replace the bushing properly. You have to remove the crimped in retaining washer to installing the new bushing. Have you tried moving the shifter from in the car with the set screw removed? That might help free the linkage off the selector shaft. If not try a small puller of sorts like one made for battery terminals. Make sure you mark the position of the shift linkage where the two shafts join and are clamped together with the 13mm bolt before removing it from the car. Otherwise getting it lined back up without the factory tool with be a PITA.

Good idea with the terminal puller. I have moved the shifter around a lot and its not budging. Im soaking it now in some ATF and acetone. It is just the single set screw thing holding the linkage on the selector right? I cannot believe how stuck it is.

loxxrider · Post by **loxxrider** » Mon Oct 06, 2014 4:18 pm

Yes, it is just the single set screw/bolt.

To answer your question from above about how I got the arm off, I just pulled like crazy with my bare hand(s). I was probably really mad at it and started to rage (no roids) on it lol.

BLAKEnwURS · Post by **BLAKEnwURS** » Tue Oct 07, 2014 8:21 pm

loxxrider wrote:Yes, it is just the single set screw/bolt.

To answer your question from above about how I got the arm off, I just pulled like crazy with my bare hand(s). I was probably really mad at it and started to rage (no roids) on it lol.

Just did the same thing pretty much and popped it off. Now how did you get the whole linkage out of the car? It feels like the end is too large to pull out through the inside of the car, like there is a small tunnel it passes through.

BLAKEnwURS · Post by **BLAKEnwURS** » Fri Oct 10, 2014 4:30 pm

Here is the old next to the new. I got the shifter aligned I hope. Now I'm struggling getting the bushing over the ball.

Loxxrider how did you do this part? Crowbar on the firewall? C clamp? It was hard enough getting it off so I'm dreading getting it on.

Sent from my iPhone using Tapatalk

loxxrider · Post by **loxxrider** » Fri Oct 10, 2014 10:14 pm

Sorry I didn't answer before, I missed that there was a new post. My memory about this whole process is very foggy. I can't even remember how I got it out of the car. I can't remember how I got the socket back on the ball either. Could have been in the car or out of it, but I think it was in. I think I remember getting it back on without prying. In fact, now I really remember because it kept popping back off after install. I'd get right back underneath the car and pop it on again after. It was never quite right and then I sent it to Marc's place. Not sure if it was the bushing itself or just bad linkage adjustment that was making it pop off. Probably just another 034 inferior part lol.

BLAKEnwURS · Post by **BLAKEnwURS** » Sun Oct 12, 2014 1:29 pm

Well I ended up using a crowbar and prying it back over the ball. SO... Its finally done and driving. Just need some minor shifter adjustments and it will be perfect.

I have done a few motor pulls, suspension installs, etc. This by far was the most frustrating thing I have done. :bangshead:

Thanks for your help guys!

loxxrider · Post by **loxxrider** » Sun Oct 12, 2014 3:45 pm

haha glad you got it in. Good job! I remember it being pretty frustrating too.

200 20v Shifter Bushing Replacement

200 20v Shifter Bushing Replacement

Re: 200 20v Shifter Bushing Replacement

Re: 200 20v Shifter Bushing Replacement

Re: 200 20v Shifter Bushing Replacement

Re: 200 20v Shifter Bushing Replacement

Re: 200 20v Shifter Bushing Replacement

Re: 200 20v Shifter Bushing Replacement

Re: 200 20v Shifter Bushing Replacement

Re: 200 20v Shifter Bushing Replacement

Re: 200 20v Shifter Bushing Replacement

Re: 200 20v Shifter Bushing Replacement

Re: 200 20v Shifter Bushing Replacement

Re: 200 20v Shifter Bushing Replacement