Hi all, I recently bought a "rebuilt" s5 NA trans, and noticed the guy never put the shift lever return spring in. I tried to remove the return spring from my old transmission, but I got the roll pin stuck in the housing. The pin is hitting on the housing behind it, so I am unable to pound the pin out. I have tried drilling it out, without much of any success.

Any advice on how to remove this? I understand that I do not need the spring, as it just returns the shifter to the neutral position, which I could just do manually.

Also I installed a new throwout bearing onto the trans, and it kinda gets hung up on the shaft when you extend the fork all the way... is this normal?

 

I believe the pin must be drilled out. Which is a real pain because it's hardened. At least that's what I've always had to do.

 

The throw out only has to go as far as the end of the input shaft's splines..MAX..the clutch plate still has to contact the input splines,so any excess movement after that is not necessary.
If you are moving the fork to the MAX then it is really exceeding the operational spec of the Parts,so in this case you need not worry about it as it will never "get there" to bind up.

 

Yeah, the bearing only sticks when I push it very far using the shift fork, so I think you are correct.

I am going to try to jimmy rig my trans underneath my drill press so I can get it out, as I have had limited success so far trying to drill it out using a had drill.
Once I get it out, couldn't I just drill and tap the hole and replace the stupid pin with a bolt, and use some loctite?