Phase 2 of my build in progress

[gsmith660]

So I popped the diff cover and inspected everything and the ring and pinion are a beautiful grey color no damage apparent ant no play at all in the pinion bearing turns smooth this is a 996.2 box with the redesigned bearing so I hope I am good also the diff housing was completely clean an no debris in the housing at all

[gsmith660]

The second gear parts are on the way Aase sales gave me a real good price pics to come soon

[gsmith660]

PARTS! The center console I’m going to use and the megasquirt stuff I need to convert to full sequential fuel and spark

[Tippy]

You’re going to run all the 996 interior parts?

[gsmith660]

Originally Posted by Tippy

You’re going to run all the 996 interior parts?

Just down the center console because of all the 996 stuff that runs outside the tunnel

[gsmith660]

The 2nd gear repair begins today I want get everything ready so reassembly can move along smartly when then new parts show up tomorrow

[gsmith660]

So the CMS shift arrester is installed


And the reverse/1st gear set is pulled I have to let my impact cool down and recharge the battery before I pull the 2nd/3rd gear set and from what I have seen so far it’s goo I ordered all the 2nd gear parts

[gsmith660]

Jobs half way done! 2nd gear is off and it took more effort than 1st and reverse. So a lot done today I also modified the 108mm stub shafts to accept 10mmbolts so I will have 6 bolts on all sides now.

[gsmith660]

It took about 4 hours to get the gears off more from equipment limitations than actual work. I had to go get another 3/8 impact adapter the one I had broke and had to charge batteries between gears I am thinking it will take less time to reassemble I think then put the case back on.

[gsmith660]

Ok a word to the wise don’t let the pucks balls and springs in the syncros go flying they are a ***** to find and the 2nd gear balls are easy to reinstall but the reverse balls are a *****

[gsmith660]

The gears are all back together and I am sorry to say I had no idea just how easy it was for springs pucks and balls pop out and it took me the better part of a day to put them back together and I hope I never see those things ever again but by the time I got it all back together I could do it pretty quick. Another issue I had was I couldn’t get the second gear syncro assembly to properly seat until disassembled it including the aforementioned parts I am not sure what was going on there but such as life but needless to say the gear stacks are back together and tomorrow the case will go back on and the trans will go under the work bench until I am ready to take it to get the limited slip put in

[gsmith660]

I tried twice to install it as an assembly lined up correctly but wouldn’t seat then I took it all apart and it went right on without even needing persuasion

[gsmith660]

Do not use persuasion on the needle bearing i did just to be sure it seated and apparently deformed it this was a 300 dollars screwup so dont do it

[Tippy]

Looks like you’re on the home stretch. Good to know these trans aren’t too difficult.

Apparently, G50’s are pretty tool and fixture intensive.

[gsmith660]

Originally Posted by Tippy

Looks like you’re on the home stretch. Good to know these trans aren’t too difficult.

Apparently, G50’s are pretty tool and fixture intensive.

I actually wish I had just paid someone to do it I had no idea the case would be so difficult to put back on and the whole puck,spring, and ball thing is just frustrating they pop out at the drop of a hat the up side is I have gotten really good at putting them back together

[gsmith660]

I got the replacement bearing ang have everything in just waiting on the circlip that had to be special ordered I didnt like the looks of the one I took off so a word to the wise plan on the circlip being deformed they are 6 bucks so when you order your parts include this on your list. Also waiting on a blind puller the one I had wouldnt get the job done for the bearing race. My advise be deliberate and smart about how you put this back together and the videos I saw said heat the components to 350-450 degrees be advised the bearing manufacture says anything over 250 starts to take the temper out of the metal so check max temp.

[gsmith660]

For those of you who are brave enough to dive into the gearbox and lose a ball or two I have several of these now so get with me.

[Ryan_Cunningham]

What do you think the total cost of the conversion will be considering all the components that have to be changed?

[gsmith660]

Originally Posted by Ryan_Cunningham

What do you think the total cost of the conversion will be considering all the components that have to be changed?

Not real sure but I am thinking it is cheaper than the G50 conversion I am into it for about 11-12 k right now with probably another 3k to go but most of that I would have to do for a G50 also considering the cheapest G50 I found rebuilt was 15k I am ahead of the cost curve and I have a 6 speed vs a 5 speed. Things left acquire are the shifter and the pedal assembly and the limited slip G50 pedal assemblies are non existent or expensive I am money ahead on that also. It all depends on the effort you want to put into it. Even a G50 needs to be broke down to modify it for an easy install and from what I have seen the cost of that is 3500 plus shipping to and from if you dont have someone local that can do it.

[gsmith660]

Originally Posted by Ryan_Cunningham

What do you think the total cost of the conversion will be considering all the components that have to be changed?

Are you an aviator Navy or Air Force? I am a submariner myself