Intermediate Shaft Gears
 

Hi everyone,

I'm looking to replace the gears on my intermediate shaft on my 71 911. I need to know if there's anything special that needs to be done or just press the old ones off and press the new ones on? This is my first 911 engine build so thanks for any input!

Sebastian

Do you mean the sprockets for the chains?

If so, there isn’t too much to do; they come off with a gear puller.

Going back in requires the gears be heated pretty hot, and the shaft cooled to minimize the press Fit

350F oven for the sprockets
Freezer for the shaft

You need to be ready to hammer it home if it just starts to heat up the shaft.

They use woodruff keys, don’t forget them

Do one at a time and then cool the partial assembly before adding the second sprocket. The heat from the first one will heat up the shaft too much.

I tried to put the second gear on right after the first and it stopped halfway and would not budge.

I had to pull it off and re-cool the shaft and reheat the loose gear.

Then it slipped on easily.

The aluminum gear is bolted. And the locktabs used are the same as the oil pump to case lock tabs.

Don’t forget the snap rings. 😉

I seem to remember a bit of a rodeo with cheap pullers. They are stuck on pretty tight. Having a press with the fittings would be nice.

I bought the heavy duty craftsman gear puller. Worked great.

Those gears are on really tight. They did not want them to move at all.

The keyway is there for a backup only.