Shift Rods Absolutely Refuse To Part.

[&Dan]

Gnnnnngh. Patience....perseverance....

Two qualities I'm having trouble keeping in reserve.

Here's the situation: '65 Bus, trans is out, shifter plate and shifter out, coupler cut off, the front and rear tube refuse to let go of each other.
It's as if they are swaged together.

I have subjected the joint, which is not explicitly rusty, to at least 50 heat/quench cycles, with a dousing of PB Blaster and an acetone/ATF mixture every 3rd or 4th cycle. It has been soaking in penetrant for nigh onto a week.

I've read every single post on the subject here, having thoroughly searched the topic, and tried every suggestion. I went in knowing what to expect and behaved accordingly. Connector gave me a hassle, I split it with a Dremel, out it came, no problem.

I have not yet become savage with the thing for fear of crushing the front rod, though it does now bear some Vise-Grip marks [well away from the joint] and I do NOT want to cut the rod. That's not an option; I do not want to wreck it. I feel bad enough about the connector, truth be told.

Twisting hasn't made it yield at all; the joint is SOLID. No movement at all. None!

Ummm.....halp?

Gracias.

[type241]

Just cut it. Shift rods are not that expensive. Welder? You have around $1,000 into now with your labor. You could be driving by now.

I ONCE spent 3 weeks on an axle nut. Guess what not anymore.
The joys of getting to know your bus.

[Emeritusx]

At least the connector is only 8 bucks... Damn, I was about to attempt the same thing, my bushings are all beat. It took three weeks to get a nut off just not too long ago... Try heating the front and hit the rear with co² (freeze) (canned duster spray)... I do know the joy you feel when you finally get it to move.
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82 Westy ☢, 66 Splitty ☮, 73 Type 181 ✠

[&Dan]

[sventinker]

[busdaddy]

Sounds like you have one option left:

They work best in pairs for that job
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[iveedubbin]

I had the same issue on my 57 SC. I let the rod and connector sit on PB Blaster for a couple of weeks and NADA. I finally just cut the connector, replaced it with one from WW and VOILA.

[Clara]

The problem is that the repro are according to some, who I believe, not quite spot on repros.

When you do the heat/quench do you get it really friggin hot?
Hot enough that there is major sizzling and steam when you squirt it with the water bottle? Visualise volcanos.

I hate the repro couplers. I bought one and installed it on my red bus, and then called up to politely let the people at WW know the ID was too big and the thing was sloppy and his attitude is well, it worked? Ya, but for $22 I wanted something that fit RIGHT. I'd have sawed a section off a pipe if I knew their repro would fit like it did. crap parts. At least if they are $8 they are not as pricey, but it was BS.

Oh ya, it has been rusting for 40+ years, let it soak in penetrating oil longer. Patience, grasshopper.
Don't squash the tubes. Twisting is key, but don't squash the shift rods.
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[&Dan]

[pyrOman]

If you have to cut the rod, do so at an angle or slant like // , not straight across. That way it will go back together exactly as it should and there be no chance of splicing it out of position. BTDT! Good luck either way!
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[Nor_AL_67]

After cutting the coupler out, I made a thin relief cut (on the front shift rod) from the hole to the end (about 1/2") long. Then used a small screw driver to pry the edges out. Removed and welded the cut up.

_________________
63 Sedan
61 Rag
67 Type 1 Sedan
63 Type 2 Standard Walk-thru
69 Ghia
68 912

Amateur Versus Rusty Bus!

[SkooobaSteve]

I cut one on each side, just got a hammer and punch and just knocked it off. Was pretty easy to do once I gave up on trying to save it..
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Jonathan
Romans 6:13
WTB 67 beetle rear seat belts.
59 Euro ragtop build with my dad
http://www.thesamba.com/vw/forum/viewtopic.php?t=493553&postdays=0&postorder=asc&start=0
65 dlx Slow build
http://www.thesamba.com/vw/forum/viewtopic.php?t=391061

[transportertalkman]

Cut it off - two slices 180 degrees out. Repros are no good. I have some NOS ones if you need it
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1951 Belgium Standard
1957 Ghia coupe
1960 Double Cab
1963 Ghia convertible
1964 Westfalia SO34
1967 Riviera Camper

[420GOAT]

Why are you trying to take them apart? i just changed my shift bushing, new coupler, new rear bushing, both dust boots(front one i cut along the seam and zip tied it). i really saw no need to fight it if frozen.
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once you realize im not impressed we will get along just fine

[splitpile]

The later front shift rod couplers from most vendors are Genuine VW (there that same as on bays also) , the early ones are a repo.

I just cut the coupler in half and knock it off, put a couple relief cuts in the rear rod, spray with PB and manipulate it apart, as stated earlier in this thread. I have also welded the cut halves back together and reused it.
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[Clara]

[SkooobaSteve]

_________________
Jonathan
Romans 6:13
WTB 67 beetle rear seat belts.
59 Euro ragtop build with my dad
http://www.thesamba.com/vw/forum/viewtopic.php?t=493553&postdays=0&postorder=asc&start=0
65 dlx Slow build
http://www.thesamba.com/vw/forum/viewtopic.php?t=391061

[Stocknazi]

if you don't want to burn your floor while heateing up the rod coupler, lay a super wet towel over the floor on the inside.

i made a small metal heat shield from a piece of stainless steel to keep the torch from burning the floor also.

iirc i had to break out the acytelene/ox torch last time i had a really rusty connector. if you don't have that mapp gas may work
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[&Dan]

Thanks very much for the advice, photos and comments, folks, we really appreciate it.

Believe me, I lay there a long time trying to dope out how to replace the bushings and boots without parting the rods- you must be some sort of magician, 420Goat!

What gets me is how little rust there is on the joint- the photos posted above show some truly stuck-looking joints- but ours looks clean.
I have to say I feel like a total puss for being apparently incapable of parting it.

Thought for sure I'd have that thing apart by the time the bushings and boots arrived from Splitpile....grrrr.
Well, we'll give it another few days of soaking and encouragement followed by threats and haranguing before we admit defeat and saw it off.

You know what really sucks? I have that ABBA song, "Waterloo", stuck in my head....aauuughh.

[zozo]